Land Rover Defender Workshop Manual

Land Rover Defender is a highly capable off-road vehicle that is perfect for exploring the great outdoors. It features a rugged design, powerful engine, and advanced technology that makes it a joy to drive on any terrain. Whether you're tackling rough trails, towing heavy loads, or simply enjoying a weekend camping trip, the Land Rover Defender is up to the task.

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TABLE OF' CONTENTS

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

Introduction

General Specification Data ...................................................................................

Engine Tuning D a t a . .

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

.I!. .............................................................

Torque Wrench Settings..

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

General Fitting Instructions

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

Recommended Lubricants, Fluids and Capacities.. .....................................................

Maintenance .....................................................................................................

Engine .............................................................................................................

. "

. . .

..I

Fuel System (including Fuel Injection) .....................................................................

Cooling System ..................................................................................................

Clutch.. ............................................................................................................

Manual Gearbox and Transfer Box .........................................................................

Propeller Shafts.. ................................................................................................

Rear Axle and Final Drive ....................................................................................

SECTION BOOK m I

El m b m I

" 1

E l

O J w

El w

Steering.. ..........................................................................................................

Suspension ........................................................................................................

Brakes .............................................................................................................

Electrical ..........................................................................................................

BOOK ONE CONTENTS

Section

Number

- Repairs and replacement parts

-Fuel handling precautions

-Fuel tank draining and repair

Location of vehicle identification numbers

GENERAL SPECIFICATION DATA

-2.25 litre petrol engine data

2.25 litre dicscl cnginc data

- 2.50 litre dicsel engine data

- Tyre pressures

Vchiclc wcights ri

ENGINE TUNING DATA

- 2.25 litre petrol engine tuning data

2.5 litre petrol engine tuning data

- 2.25 and 2.50 litre dicscl engine tuning data

- .

TOR Q UE WRENCH SETINGS

Page

.E.

Book One Contents (cont’d)

Section

GENERAL FITTING INSTRUCTIONS

- Precautions against damage

-Safety precautions

- Preparation and dismantling

- Inspection of components

-Ball and roller bearings

- Joints and joint faces

- Tab washers, split pins, nuts and locking wire

1091

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

- Corrosion inhibitor

-Capacities

- Maintenance Schedules

- Maintenance

- Maintenance -

5 :

...

..:I.

INTRODUCTION

This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be completed within t h e time stated in the 'Repair Operation Times'.

The Manual has been produced in separate books; this allows the information to be distributed throughout the specialist areas of the modern service facility.

A table of contents in Book 1 lists the major components and systems together with the section and book numbers.

The cover of each book details the sections contained within that book.

The title page of each book carries the part numbers required to order replacement books, binders or complete

Service Manuals. This can be done through the normal channels.

REFERENCES

References to the left- or right-hand side in the manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the water pump end of the engine is referred to as the front.

To reduce repetition, operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned.

DIMENSIONS

The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification.

During the period of running-in from new, certain adjustments may vary from the specification figures given in this

Manual. These adjustments will be re-set by the Distributor or Dealer at the After Sales Service, and thereafter should be maintained at the figures specified in the Manual.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential that only Land Rover parts are used.

Attention is particularly drawn to the following points concerning repairs and the fitting o f replacement parts and accessories:

Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer's specification. Torque wrench setting figures given in the Repair Operation Manual must bc strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement may be invalidated by the fitting of other than Land Rover parts.

A11 Land Rover parts have the full backing of the Owners Service Statement.

Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts.

POISONOUS SUBSTANCES

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should as far as possible be kept away from open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines the other areas of risk which must not be ignored.

This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of your local Fire Officer.

. ....

GENERAL

Petrol/gasoline vapour is highly flammable and in confined spaces is also very explosive and toxic.

When petroI/gasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is potentially very dangerous.

4 lo1 I

Always have a fire extinguisher containing FOAM CO? GAS, o r POWDER close at hand when handling or draining fuel, o r when dismantling fuel systems and in areas whcre fuel containers are stored.

Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system.

Whenever petroVgasoline is being handled, drained or stored, o r when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any hcad-lamps used must be flameproof and kept clear of spillage.

NO O N E SHOULD BE PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL/

GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.

FUEL TANK DRAINING

WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST

IS

STANDING OVER A PIT.

Draining or extracting petrol/gasoline from vehicle fuel tank must be carried out in a well ventilated area.

The receptacle used to contain the petroVgasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations.

WHEN PETROWGASOLINE HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK THE

PRECAUTIONS GOVERNING NAKED LIGHTS AND IGNITION SOURCES SHOULD BE MAINTAINED. fi-- k.

FUEL

TANK

REMOVAL

On vehicles where the fuel line is secured to the fuel tank outlet by a spring steel clip, it is recommended that such clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedure will avoid the possibility of residual petrol fumes in the fuel tank being ignited when the clips are released.

As an added precaution fuel tanks should have a PETROUGASOLINE VAPOUR warning label attached to them as soon as they are removed from the vehicle.

FUEL

TANK

REPAIR

Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following methods:

STEAMING: With the filler cap and tank unit removed, empty the tank. Steam the tank for at least two hours with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any sediment and sludge not volatised by the steam, is washed out during the steaming process.

BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling water containing an effective alkaline degreasing agent or a detergent, with t h e water filling and also surrounding the tank for at least two hours.

After steaming o r boiling a signed and dated label to this effect should be attached to the tank

SPECIFICATION

Purchasers arc advised that the specification details set out in this Manual apply to a rangc of vehicles and not to any one. For the specification of a particular vehicle, purchasers should consult their Distributor o r Dealer.

The Manufacturers reserve thc right to vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer's policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the

Manufacturer nor the Distributor or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thercof.

COPYRIGHT

@Land Rover Limited 1984

All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording or other means without prior written permission of Land

Rover Limited, Service Department, Solihull, England.

Special

Service

Tools

The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. The amount of time which they save can be considerable.

Every special tool is designed with the close co-operation of Land Rover Ltd., and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely.

Special tools bulletins will be issued periodically giving details of new tools as they are introduced.

All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill.

Overseas orders should be placed with the local V. L. Churchill distributor, where one exists.

Countfies where there is no distributor may order direct from V. L. Churchill Limited. P.O.

Box 3, Daventry, Northamptonshire, England N N l l 4NF.

The tools recommended in this Workshop Manual are listed in a multi-language, illustrated catalogue obtainable from Messrs. V. L. Churchill at the above address under publication number 2217/2/84 or from Land Rover Ltd., under part number LSM0052TC from thc following address, Land Rover Limited, Service Department, Lode Lane,

Solihull, West Midlands, England B92 8NW.

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS

VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate riveted to the top of the brake pedal box in the engine compartment.

The number is also stamped on the right-hand side of the chassis forward of the spring mounting turret.

Always quote this number when writing to Land Rover

Limited.

Key to Vehicle Identification Number Plate

A

Type approval

B

VIN (minimum of 17 digits)

C Maximum permitted laden weight for vehicle

D Maximum vehicle and trailer weight

E Maximum road weight -

F

Maximum road weight

ENGINE SERIAL NUMBER

ENGINES

4 CYLINDER

The 4 cylinder engine number is stamped on a machined surface at the front left-hand side of the engine adjacent to the exhaust manifold front flange.

O n later engines the number is stamped above the rear side cover, as the second illustration shows.

6”

TOO1

I f A N D

&IR

ST037

ENGINE SERIAL NUMBER

The

V8

engine serial number is stamped on a cast pad on the cylinder block between numbers 3 and 5 cylinders.

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS 01

ST664M

TRANSFER GEARBOX LT230T

AND V8 VEHICLES FROM SERIAL NUMBER

SUFFIX ‘B’ ONWARD

ST663M

FRONT AXLE

Stamped on top of the left-hand axle tube.

REAR AXLE

Stamped on rear of left-hand axle tube.

MAIN GEARBOX LT77

Stamped on a pad on the right-hand side of the gearbox immediately below the oil filler level plug.

MAIN GEARBOX LT85 FIVE SPEED

VEHICLES

Stamped on the right-hand side of the front bearing plate.

ST665M

TRANSFER GEARBOX LT230R

VEHICLES

Stamped on the casing on the left-hand side of the gearbox below the mainshaft rear bearing housing adjacent to the bottom cover.

STl546M

G EN ERA L SPECIFICATION DATA 04

ENGINE

Type .................................................................

Number of cylinders .............................................

Bore .................................................................

Stroke ...............................................................

Capacity ............................................................

Valve operation.. .................................................

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

Maximum power

- ......................................

Maximum torque .................................................

Eight, two banks of four

88,90 mm (3.500 in)

71,12 mm (2.800 in)

3528 cc (215 in')

} at 4000rpm

251 Nm (185 lb ft) at 2500 rpm

. .

Crankshaft

Main journal diameter .......................................

Minimum regrind diameter ..............................

Crankpin journal diameter. .................................

Minimum regrind diameter ..............................

Crankshaft end thrust ........................................

Crankshaft end-float ..........................................

58,409

58,422 m m (2.2996 - 2.3001 in)

57,393 - 57,406 mm (2.2596 - 2.2601 in)

50,800 - 50,812 mm (2.0000 - 2.0005 in)

49,784 - 49,797 mm (1.9600

1.9605 in)

Taken on thrust washers of centre main bearing

0,lO

0,20 m m - 0.008 in)

Main bearings

Number and type .............................................. 5 , Vandervell shells

Material .........................................................

Diametrical clearance ........................................

Lead-indium

0,010 - 0,048 mm (0.0004

0.0019 in)

Undersizes ...................................................... 0,254 mm, 0,508 mm (0.010 in, 0.020 in)

Connecting rods

Type.. ............................................................ Horizontally split big end, pIain small end

Length between centres ...................................... 143,81 - 143,71 mm (5.662

5.658 in)

Big end bearings

Type and material .............................................

Diametrical clearance .......................................

End-float on crankpin .......................................

Undersizes ......................................................

Vandervell VP lead-indium

0,015 - 0,055 mm (0.0006 - 0.0022 in)

0,15 - 0,36 mm (0.006

0.014 in)

0,254 mm, 0,508 mm (0.010 in, 0.020 in)

Gudgeon pins

Length ...........................................................

Diameter ........................................................

72,67 - 72,79 mm (2.861 - 2.866 in)

22,215 - 22,22 mm (0.8746 - 0.8749 in)

Fit-in connecting rod ......................................... Press fit

Clearance in piston ............................................ 0,002 - 0,007 mm (0.0001 - 0.0003 in)

Pistons

Clearance in bore measlured at hottom of skirt at right angles to gudgeon pin .................................. 0,018 - 0,033 mm (0.0007 - 0.0013 in)

1041

GENERAL SPECIFICATION DATA

Piston rings

Number of compression

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

Number of oil ..................................................

No. 1 compression ring

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

No. 2 compression ring.. .....................................

Width of compression rings .................................

Compression ring gap ........................................

Oil ring type ....................................................

Oil ring width. ..................................................

Oil ring gap .....................................................

Chrome parallel faced

Stepped to 'L' shape and marked 'T' or 'TOP'

1,56 - 1,59 mm (0.0615 - 0.0625 in)

0,44 - 0,57 mm (0.017 - 0.022 in)

Perfect circle, type 98-6

4,811 mm (0.1894 in) max

0,38 - 1,40 mm (0.015 - 0.055 in)

Camshaft

Location ......................................................... Central

Bearings ......................................................... Non-serviceable

Number of bearings ........................................... 5

Drive ............................................................. Chain 9,52 mm (0.375 in) pitch x 54pitches

Valves

Length:

Inlet ...........................................................

Exhaust.. .....................................................

Seat angle:

Inlet ...........................................................

Exhaust.. .....................................................

Head diameter:

Inlet ...........................................................

Exhaust.. .....................................................

Stem diameter: inlet ...........................................................

Exhaust .......................................................

Stem t o guide clearance:

Inlet ...........................................................

Exhaust .......................................................

Valve lift (inlet and exhaust). ...............................

Valve spring length fitted ....................................

116,59 - 117,35 mm (4.590 - 4.620 in)

39,75 - 40,OO mm (1.565

1.575 in)

34,226 - 34,480 mm (1.3475 - 1.3575 in)

8,664 - 8,679 mm (0.3411

8,651 - 8,666 mm (0.3406

0.3417 in)

0.3412 in)

0,025 - 0,066 mm (0.0010 - 0.0026 in)

0,038 - 0,078 mm (0.0015

0.0031 in)

9,49 mm (0.374 in)

40,4 mm (1.590 in) at pressure of 2 9 3 kg (65 lbs)

Lubrication

System ...........................................................

System pressure, engine warm at 2400 rpm .............

Wet sump, pressure fed

2 , l - 2,8 kgf cm2 (30

40 Ibf in2)

Oil filter (external). ........................................... Full-flow, self-contained cartridge

Oil filter (internal) ............................................

Oii pump type ..................................................

Gauze. Pump intake filter

Gear

Oil pressure reIief valve

Type .............................................................. Non-adjustable

Relief valve spring:

Free length ...................................................

Compressed length at 4,2 kg (9.3 lb) load ............

81,2 mm (3.2OO in)

45,7 m m

Oil filter by-pass valve

Type ............................................................... Non-adjustable

By-pass valve spring:

Free length ................................................... 37,5 mm (1.48 in)

Compressed length at 0,34

kg

(0.75

lb).

............... 22,6 mm (0.89 in)

GENERAL SPECIFICATION DATA

1041

2.25

LITRE

PETROL ENGINE i’. ’. ‘1

ENGINE

Type .................................................................

Bore .................................................................

Stroke ...............................................................

Capacity ............................................................

Valve operation. ..................................................

Compression ratio.. ..............................................

Maximum power @ 4000 rpm .................................

Maximum torque @ 2000 rpm.. ...............................

90,47 mm (3.562 in)

88,9 (3.500 in)

2286 cm3 (139.500 in3)

Overhead by push-rod

8.0: 1

55.2 Kw (74 bhp)

163 Nm (120 Ibf ft)

Crankshaft

Main journal diameter .......................................

Minimum regrind diameter ..............................

63,487 - 63.500 mm (2.4995 - 2.500 in)

63,246

63,2333 mm (2.4900 - 2.4895 in)

Crankpin journal diameter .................................. 58,725

58,744 mm (2.312 - 2.31275 in)

Minimum regrind diameter .............................. 58,48985

58,47080 mm (2.30275 - 2.30200 in)

Crankshaft end thrust ........................................ Taken on thrust washers at centre main bearing

Crankshaft end-float .......................................... 0,05 . - 0.006 in)

Main bearings

Number and type ..............................................

Material .........................................................

Diametrical clearance ........................................

Undersizes ......................................................

5 halved shells

Steel shell, tin-aluminium lined

0,020

0,063 mm (0.0008

0.0025 in)

0,25 mm (0.010 in)

Connecting rods

Type ..............................................................

Length between centres.. ....................................

Horizontally split big end, plain small end

175,36 - 175,46 mm (6.904 - 6.908 in)

.I.

. ,

Big end bearings

Type and material .............................................

Diametrical clearance

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

End-float on crankpin ........................................

Undersizes ......................................................

Steel shell, copper-lead lined

0,019 - 0,068 mm (0.00075 - 0.0027 in)

0,20

0,30 mm (0.007

0.012 in)

0,25 mm (0.010 in)

Gudgeon pins

Type .............................................................. Floating

Fit in piston .....................................................

Push

fit by hand

Clearance in connecting rod ................................ 0,007 - 0,015 mm (0.0003

0.0006 in)

Pistons

Type 8.O:l compression ratio ...............................

Clearance in bore, measured at bottom of skirt at

Aluminium alloy, flat top right angles to gudgeon pin:

Standard size pistons

Oversize pistons

...................................... 0,06

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

0,043

0,07 mm (0.0023

- 0,055 m m (0

0.0027 in)

0017 0 0022

104 I

GENERAL SPECIFICATION DATA

Piston rings

Compression

Gap in bore

................................................... 2

.................................................. 0,38 - 0 3 0 mm (0.015

0.020 in)

Clearance in groove.. ...................................... 0,046 - 0,097 mm (0.0018 - 0.0038 in)

Oil control ...................................................... 1

Gap in bore .................................................. 0,38 - 0,50 mm (0.015 - 0.020 in)

Clearance in groove.. ...................................... 0,038 - 0,089 mm (0.0015

0.0035 in)

Camshaft

Location .........................................................

End-float ........................................................

Number of bearings ...........................................

Material .........................................................

Drive .............................................................

Right-hand side (thrust side) of engine

0,06 - 0,13 mm (0.0025 - 0.0055 in)

Steel shell, white metal lined

Chain

Valves

Length:

Inlet ...........................................................

Exhaust.. .....................................................

Seat angle:

Inlet ...........................................................

Exhaust .......................................................

Head diameter:

Inlet ...........................................................

Exhaust .......................................................

Stem diameter:

Inlet ...........................................................

Exhaust.. .....................................................

Stem to guide clearance:

Inlet ...........................................................

Exhaust.. .....................................................

Valve lift:

Inlet ...........................................................

Exhaust.. .....................................................

111,20 - 111,66 mm (4.378

4.396 in)

111,22 - 111,58 mm (4.388 - 4.412 in)

30"

45"

44,32 - 44,57 mm (1.744 - 1.755 in)

34,93 - 35,18 mm (1.378 - 1.380 in)

7,899 - 7,912 mm (0.3109 - 0.3115 in)

8,682 - 8,694 mm (0.3418 - 0.3422 in)

0,033 - 0,048 mm (0.0013 - 0.0019 in)

0,058 - 0,073 mm (0.0023 - 0.0029 in)

10,236 mm (0.403 in)

9,85 mm (0.388 in)

Valve springs

Type.. ............................................................ Duplex interference coil

Inner:

Length, free .................................................

Length, under 8,O

kg

(17.7 Ib) load ....................

42,67 mm (1.680 in)

37,13 mm (1.462 in)

Outer:

Length, free ................................................. 46,28 mm (1.822 in)

Length, under 21 kg (46 lb) load.. ...................... 40,30 mm (1.587 in)

Lubrication

System ...........................................................

System pressure, engine warm at 2000 rpm .............

Oil pump: Early type

Type ...........................................................

Drive ..........................................................

End-float of gears:

Steel gear .....................................................

Aluminium gear ............................................

Radial clearance of gears .................................

Backlash of gears.. .........................................

Wet sump, pressure fed

2,45 - 4,50 kgf cm2 (35 - 65 lbf in2)

Double gear shaft frnm c m s h a f t skew gear

0,05

0,07 - 0,15 m m

0,02

0,12 mm (0.002

0.005 in)

0,lO m m

0.006 in)

(0.001 - 0.004 in)

0,15

0,28 mm (0.006 - 0.012 in)

GENERAL S P EC IFIC A TI ON DATA

104

......

:..

.;-....

,*. ..:

).,. ..:.

Lubrication (continued)

Oil pump: Latest type

Type

Drive

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

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

End-float of both gears .......................................

Double gear, 10 teeth, sintered iron gears

Splined shaft from camshaft skew gear

0,026

Radial clearance of gears ................................. 0,025

0,135 mm (0.0009

0,075 mm (0.0008

0.0045 in)

0.0025 in)

Backlash of gears.. ......................................... 0,l - 0,2 mm (0.0034 - 0.0067 in)

Oil pressure relief valve

Type .............................................................. Non-adjustable

Relief valve spring:

Full length .................................................... 67,82 mm (2.670 in)

Compressed length at 2,58 kg (5.7 lb) load ........... 61,23 mm (2.450 in)

2.5

LITRE PETROL ENGINE

ENGINE

Type .................................................................

Bore .................................................................

Stroke

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

Capacity

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

Valve operation.. .................................................

Compression ratio.. ..............................................

Maximum power @ 4000 rpm

Commencing serial no..

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

Maximum torque @ 2000 rpm..

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

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

4 cylinder

90,47 mm (3.562 in)

97 mm (3.82 in)

2495 cm3 (152.25 in3)

Overhead by push-rod

8.0: 1

59.5 Kw (80 bhp)

175 Nm (129 Ibf ft)

17H00011C

Crankshaft

Main journal diameter

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

63,487

63,500 mm (2.4995

2.500 in)

Minimum regrind diameter .............................. 63,246 - 63,2333 mm (2.4900 - 2.4895 in)

Crankpin journal diameter .................................. 58,725

58,744 mm (2.312

Minimum regrind diameter

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

58,48985

2.31275 in)

58,47080 mm (2.30275

2.30200 in)

Crankshaft end thrust ........................................ Taken on thrust washers at centre main bearing

Crankshaft end-float.. ........................................ 0,05 - 0,15 mm (0.002 - 0.006 in)

Main bearings

Number and type ..............................................

Material

5 halved shells

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

Copper-lead lined

Diametrical clearance

Undersizes

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

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

0,018

0,06 mm (0.0007

0.0026 in)

0,25 mm (0.010 in)

Connecting rods

Type .............................................................. Horizontally split big end, plain small end

Length between centres ...................................... 175,36 - 17546 mm (6.904 - 6.908 in)

, . .

Connecting rod bearings

Type and material

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

Steel shell, copper-lead lined

Diametrical clearance ........................................

End-float on crankpin

0,025

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

0,20

0,075 mm (0.001

0,30 mm (0.007

- 0.003 in)

0.012 in)

Undersizes ...................................................... 0,25 mm (0.010 in)

104

G E N ERAL SP E C IFI C A TION DA TA

Gudgeon pins

Type

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

Fit in piston .....................................................

Clearance in connecting rod ................................

Floating

Push fit by hand

0,007 - 0,015 mm (0.0003 - 0.0006 in)

Pistons

Type 8.0: 1 compression ratio ...............................

Clearance in bore measured @ 17 mm from bottom of skirt at right angles to gudgeon pin:

Standard and oversize pistons ...........................

Aluminium alloy. Recessed crown.

0,043 - 0,067 mm (0.0017.- 0.0026 in)

Piston rings

Compression ...................................................

Gap in bore ..................................................

Clearance in groove ........................................

Oil control ......................................................

Gap in bore ..................................................

Clearance in groove ........................................

0,40 - 0,65 mm (0.016 - 0.026 in)

0,046 - 0,097 m m - 0.0038 in)

0,30 - 0,55 mm (0.012 - 0.022 in)

0,026 - 0,076 mm (0.0012

0.003 in)

Camshaft

Location .........................................................

End-float ........................................................

Right-hand side (thrust side) of engine

0,06 - 0,13 mm (0.0025 - 0.0055 in)

Number of bearings ........................................... 4

Material ......................................................... Steel shell, white metal lined

Drive ............................................................. 76 link chain

Valves

Length :

Inlet ...........................................................

Exhaust.. .....................................................

Seat angle:

Inlet ...........................................................

Exhaust.. .....................................................

Head diameter:

Inlet ...........................................................

Exhaust.. .....................................................

Stem diameter:

Inlet ...........................................................

Exhaust,. .....................................................

Stem to guide clearance:

Inlet ...........................................................

Exhaust .......................................................

Valve lift:

Inlet ...........................................................

Exhaust .......................................................

Exhaust valve seat insert:

External diameter.. ........................................

Internal diameter.. .........................................

Width .........................................................

Seat angle and depth .......................................

111,20- 111,66mm (4.377 -4.396in)

1 1,12 - 1 - 4.393 in)

30"

45"

44,32 - 44,58 mm (1.744 - 1.755 in)

34,43 - 34,18 mm (1.355 - 1.345 in)

7,899 - 7,912 mm (0.3109 - 0.3115 in)

8,697 - 8,679 mm (0.3424 - 0.3416 in)

0,033 - 0,048 mm (0.0013

0.0019 in)

0,035 - 0,076 mm (0.0014 - 0.0022 in)

10,236 mm (0.403 in)

9,85 mm (0.388 in)

36,576 - 36,601 (1.440 - 1.441 in)

28,448

28,702 mm (1.120 - 1.130 in)

5,055 - 5,105 mm (0.199 - 0.201 in)

45". 0,635 - 0,889 iiiiii

( 0 . m

0.035

in;

GENERAL SPECIFICATION DATA

1041

,,:?.%

Valve springs

....

Type .............................................................. Duplex interference coil

Inner:

Length, free ................................................ 42,67 mm (1.680 in)

Length, under 8,0 kg (17.7 Ib) load .................... 37,13 mm (1.462 in)

Outer:

Length, free .................................................

Length, under 21 kg (46 Ib) load ........................

46,28 mm (1.822 in)

40,30 mm (1.587 in)

- .

. . .

Lubrication

System ...........................................................

System pressure, engine warm at 2000 rpm .............

Oil pump:

Type ...........................................................

Drive ..........................................................

End-float of both gears.. .....................................

Radial clearance of gears .................................

Backlash of gears ...........................................

Wet sump, pressure fed

2,45

4,50 kgf cm2 (35 - 65 Ibf in2)

Double gear, 10 teeth, sintered iron gears

Splined shaft from camshaft skew gear

0,026 - 0,135 mm (0.0009

0.0045 in)

0,025 - 0,075 mm (0.0008 - 0.0025 in)

0,l - 0,2 mm (0.0034 - 0.0067 in)

Oil pressure relief valve

Type ..............................................................

Relief valve spring:

Full length ....................................................

Compressed length at 2,58 kg (5.7 lb) load ...........

Non-adjustable

67,82 m m (2.670 in)

61,23 mm (2.450 in)

2.25 LITRE DIESEL ENGINE

ENGINE

Type .................................................................

Bore .................................................................

Stroke ...............................................................

Capacity ............................................................

Valve operation. ..................................................

Compression ratio.. ..............................................

Maximum power .................................................

Maximum torque .................................................

4 cylinder

90,47 mm (3.562 in)

88,9 mm (3.500 in)

2286 cm3 (139 in3)

Overhead by push-rod

23:l

44Kw (59 bhp) at 4000 rpm

136 N m (100 Ibf ft) at 1800 rpm

Crankshaft

Main bearing journal diameter.. ........................... 63,487 - 63,500 mm (2.4995 - 2.500 in)

Regrind dimensions:

63,246 - 63,2333 mm (2.490 - 2.4895 in) ............... Use 0.010 in

U/S

bearings

Crankpin journal diameter .................................. 58,725

58,744 mm (2.312

2.31275 in)

Regrind dimensions:

58,48985

58,4708 mm (2.30275 - 2.30200 in). ....... Use 0.010 in U/S bearings

Crankshaft end thrust ........................................ Taken on thrust washers at centre main bearing

Crankshaft end-float .......................................... 0,05 - 0,15 mm (0.002 - 0.006 in)

Main bearings

Number and type ..............................................

Material .........................................................

Diametrical clearance ........................................

5 halved shells

Steel shell, copper-lead lined, tin plated

0,020 - 0,063 mm (0.0008 - 0.0025 in)

GENERAL SPECIFICATION DATA

Connecting rods

Type ..............................................................

Length between centres ......................................

Horizontally split big end, plain small end

175,38 - 175,43 mm (6.905

6.907 in)

Big end bearings

Type and material .............................................

Diametrical clearance ........................................

End-float on crankpin. .......................................

Steel shell, copper-lead lined

0,020 - 0,0635 mm (0.0008 - 0.0025 in)

0,15 - 0,356 mm (0.006

0.014 in)

Gudgeon pins

Type .............................................................. Floating

Fit in piston .....................................................

Clearance in connecting rod ................................

Diameter ........................................................

Push fit by hand

0,0196 - G,0036 mm (0.0007 - 0.00014 in)

30,1564 - 30,1625 m m (1.18726

1.1875 in)

-. Pistons

Type.. ............................................................

Clearance in bore, measured at bottom of skirt at right angles to gudgeon pin:

Standard size pistons ......................................

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

Aluminium alloy, with V shape recess in crown

0,111 - 0,134 mm (0.0044 -0.0053 in)

0,111

0,157 mm (0.0044 - 0.0062 in)

Piston rings

Compression No. 1 (top):

Type ...........................................................

Gap in bore ..................................................

Clearance in groove.. ......................................

Compression Nos. 2 and 3:

Type ...........................................................

Gap in bore ..................................................

Clearance in groove ........................................

Oil control No. 4:

Type ...........................................................

Gap in bore ..................................................

Clearance in groove ........................................

Square friction edge, chrome plated

0,35 - 0,50 mm (0.014 - 0.019 in)

0,06 - 0,11 mm (0.0025 - 0.0045 in)

Bevelled friction edge. Marked 'T' or 'TOP' on upper side

0,25 - 0,38 mm (0.010 - 0.015 in)

0,06 - 0,11 mm (0.0025 - 0.0045 in)

Ring and spring

0,279 - 0,406 mm (0.011

0.016 in)

0,038 - 0,064 mm (0.0015 - 0.0025 in)

Valves

Length:

Inlet ...........................................................

Exhaust.. .....................................................

Seat angle:

Inlet ...........................................................

Exhaust .......................................................

Head diameter:

Inlet ...........................................................

Exhaust.. .....................................................

Stem diameter:

- ........................................................... cxnausr .......................................................

Stem to guide clearance:

Inlet ...........................................................

Exhaust.. .....................................................

Valve lift:

Inlet ...........................................................

Exhaust .......................................................

116,26 - 116,51 mm (4.377 - 4.587 in)

116,79 - 117,25 mm (4.598 - 4.616.in)

45"

39,12 - 39,37 mm (1.540 - 1.550 in)

33,25 - 33,50 mm (1.309 - 1.318 in)

7,912 - 7,899 mm (0.3114 - 0.3109 in)

8,682 - 8,694 mm (0.3418 - 0.3422 in)

0,033 - 0,048 mm (0.0013

0,058 - 0,073 mm (0.0023

0.0019 in)

0.0029 in)

9,85 m m

10,26 mm (0.404 in)

G ENERAL SP E C IFIC A T I O N DA T A

104 I

Camshaft

Location

End-float

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

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

Right-hand side (thrust side) of engine

0 , l - 0,2 mm (0.004 - 0.008 in)

Number of bearings ........................................... 4

Material

Drive

......................................................... Steel shell, white metal lined

............................................................. Chain

Valve springs

Type .............................................................. Duplex Interference double coil

Inner:

Length, free ................................................. 42,67 mm (1.680 in)

Length, under 8,O kg (17.7 Ib) load .................... 40,30 mm (1.587 in)

Outer:

Length, free .................................................

Length, under 21 kg (46 Ib) load ........................

46,28 mm (1.822 in)

40,30 mm (1.587 in)

*...

,..

Lubrication

System ...........................................................

System pressure, engine warm at 2000 rpm .............

Oil pump:

Type ...........................................................

Drive ..........................................................

End-float of gears:

Steel gear .....................................................

Aluminium gear ............................................

Radial clearance of gears ..... ......................

Backlash of gears ...............................

Wet sump, pressure fed

2,5 - 4,57 kgf cm2 (35 - 65 Ibf in2)

Double gear

Splined shaft from camshaft skew gear

0,05 - 0,12 mm (0.003 - 0.005 in)

0,07 - 0,15 mm (0.003 - 0.006 in)

0,02 - 0,lO mm (0.001 - 0.004 in)

0,15 - 0,28 mm (0.006 - 0.012 in)

Oil pressure relief valve

Type .............................................................. Non-adj ust able

Relief valvc spring:

Full length .................................................... 67,82 mm (2.670 in)

Compressed length at 2,58 kg (5.7 Ib) load ........... 61,23 mm (2.450 in)

...

2.5 LITRE DIESEL ENGINE

ENGINE

Number of cylinders .............................................

Bore .................................................................

Strokc ...............................................................

Capacity .................... .......................

Compression ratio. ...............................................

Piston area (total) ........ .................................

Maximum power at 4000 .......................

Maximum torque at 1800 rpm ...........................

90,47 mm (3.562 in)

97,OO mm (3.819 in)

2495 cc

21:l

257,l cm3 (39.86 in3)

65.5 bhp

113 Ibf ft

. .

Crankshaft

Main bearing journal diameter.. ........................... 63,487 - 63,500 mm (2.4995 - 2.5000 in)

Regrind dimensions:

63,246 - 63,2333 mm (2.490 - 2.4895 in). .............. Use 0.010 in U/S bearings

Crankpin journal diameter .................................. 58,725 - 58,744 mm (2.312 - 2.31275 in)

Regrind dimensions:

58,48985 - 58,4708 mm (2.30275 - 2.30200 in) ........

Crankshaft end thrust ........................................

Crankshaft end-float.. ........................................

Use 0.010 in U/S bearings

Taken on thrust washers at centre main bearing

0,05

0,15 mm (0.002 - 0.006 in)

04 G ENERAL S P E C I FICA T ION DATA

Main bearings

Number and type.. ............................................

Diametrical clearance ........................................

5 halved shells

0,018

0,061 mm (0.0007 - 0.0024 in)

Connecting rods

Length between centres.. ....................................

Diametrical clearance (big-end bearings). ...............

End-float on crankpin ........................................

175,38 - 175,43 m m - 6.907 in)

0,025 - 0,075 mm (0.001 - 0.003

0,15 - 0,356 mm (0.006 - 0.014 in)

Pistons

Type ..............................................................

Skirt diametrical clearance (at right angle to gudgeon pin) ........................................

Aluminium alloy 'V' shaped valve recess in crown

0,025

0,05 mm (0.001 - 0.002

Gudgeon pins

Type ..............................................................

Fit in piston .....................................................

Diameter ........................................................

Clearance in connecting rod ................................

Floating

Hand push fit

30,1564 - 30,1625 mm (1.18726 - 1.18750 in)

0,0196 - 0,0036 mm (0.00077 - 0.00014 in)

Piston rings

Type: Top ...................................................

Second ...............................................

Oil control ..........................................

Square friction edge, chrome plated

Taper faced

Expander and rails

Camshaft

Drive .............................................................

Location .........................................................

End-float ........................................................

Number of bearings.. .........................................

Material .........................................................

25,4 mm (0.1 in) wide dry toothed belt

Right-hand side (thrust side)

0 , l - 0,2 mm (0.004 - 0.008 in)

Steel shell, white metal lined

Valves

Seat angle:

Inlet ...........................................................

Exhaust .......................................................

Head diameter:

Inlet ...........................................................

Exhaust .......................................................

Valve lift:

Inlet ...........................................................

Exhaust .......................................................

Cam lift:

Inlet ...........................................................

Exhaust .......................................................

Stem diameter: inlet ...........................................................

Exhaust.. .....................................................

45"

39,12 - 39,37 mm (1.540 - 1.550 in)

33,25 - 33,50 m m - 1.319 in)

9,85 mm (0.388 in)

10,26 m m

6,81 mm (0.268 in)

7,06 mm (0.278 in)

7,912

7,899 mm (0.3114

0.3109 in)

8,682

8,694

(0.3418

- 0.3422 in)

. I

......

. .

1 .

GENERAL SPECIFICATION DATA

.,: -, r,y;:.:;>:!

.._

Valve springs

Type .............................................................. Duplex Interference double coil

Inner:

Length, free ................................................. 42,67 mm (1.680 in)

Length, under 8,O kg (17.7 lb) load .................... 40,30 mm (1.587 in)

Outer:

Length, free ................................................. 46,28 mm (1 A22 in)

Length, under 21

kg

(46 lb) load ........................ 40,30 mm (1.587 in)

.._

.A<?..

....

. .

': .

Lubrication

System ...........................................................

System pressure, engine warm at 2000 rpm .............

Oil pump: Early type

Type ...........................................................

Drive ..........................................................

End-float of gears:

Steel gear .....................................................

Aluminium gear ............................................

Radial clearance of gears .................................

Backlash of gears.. .........................................

Oil pump: Latest type

Type ...........................................................

Drive ..........................................................

End-float of both gears.. .....................................

Radial clearance of gears .................................

Backlash of gears ...........................................

Wet sump, pressure fed

2,5 - 4,57 kgf cm2 (35 - 65 Ibf in2)

Double gear

Splined shaft from camshaft skew gear

0,05 - 0,12 mm (0.002 - 0.005 in)

0,07 - 0,15 mm (0.003 - 0.006 in)

0,02

0,lO mm (0.001 - 0.004 in)

0,15

0,28 mm (0.006 - 0.012 in)

Double gear, 10 teeth, sintered iron gears

Splined shaft from camshaft skew gear

0,026 - 0,135 mm (0.0009 - 0.0045 in)

0,025 - 0,075 mm (0.0008 - 0.0025 in)

0,l - 0,2 mm (0.0034 - 0.0067 in)

Oil pressure relief valve

Type .............................................................. Non-adjustable

Relief valve spring:

Full length .................................................... 67,82 mm (2.670 in)

Compressed length at 2,58 kg (5.7 Ib) load ........... 61,23 mm (2.450 in)

GENERAL DATA

FUEL SYSTEM

Carburetter ........................................................

Air cleaner.. .......................................................

See 'ENGINE TUNING DATA'

Oil bath with built-in centrifugal pre-cleaner

Fuel pump

Type ..............................................................

Pressure range .................................................

Mechanical with sedimcnt bowl and hand primer

3 - 5 psi

Fuel pump -

Make and Type

Pressure range

................................................ Facet, electric. Mounted on R.H. side of chassis

................................................. 3 - 5 psi

.....

FUEL SYSTEM -

Injection pump.. .................................................. See 'ENGINE TUNING DATA'

Fuel lift pump type ............................................... Mechanical, with hand primer

Pressure range .................................................... 0,35 - 0 3 6 kgf cm2 ( 5

8 Ibf ft2)

104 I

GENERAL SPECIFICATION DATA

FUEL SYSTEM

Carburetter

........................................................ See ‘ENGINE TUNING DATA’

Fuel pump - Make, type ...................................... Facet, electric mounted vertically on R.H. side of chassis

Air cleaner.. ....................................................... Cyclonc, replaceable element

COOLING SYSTEM

Type.. ...............................................................

Thermostat ........................................................

Pressure cap .......................................................

Type of pump .....................................................

Pressurized spill rcturn system with thermostat control, pump and fan assisted

82°C

0,6 kgf cm2 (9 lbf in’)

Centrifugal

COOLING SYSTEM

Type.. ............................................................... Pressurized spill return system with thermostat control, pump and fan assisted

Thermostat ........................................................

Type of pump

Emission and non-emission 82”C, Australia 88°C

..................................................... Centrifugal

CLUTCH

Type .................................................................

Centre plate diameter ...........................................

Facing material ...................................................

Facing material identification colour ........................

Number of damper springs .....................................

Borg and Beck diaphragm spring

242,l mm (9.500 in)

Raybestos 1488-05

Whitdviolet on pcriphary

Damper spring colour ........................................... Dark grey/light green

Clutch release bearing. .......................................... Ball journal

CLUTCH

Type.. ............................................................... Verto diaphragm spring

Centre plate diameter ...........................................

Facing material ...................................................

Number of damper springs .....................................

Damper spring colour.. .........................................

242,l mm (9.500 in)

Raybestos 1488-05

2 off white/green

2 off pigeon blue

Clutch release bearing.. .........................................

4 off ruby red

Ball journal

CLUTCH

Type.. ............................................................... Verto diaphragm spring

Centre plate diameter (friction plate) ....................... 235 mm (9.25 in)

Facing material ................................................... Verto 791

Number of damper springs ..................................... 8

Damper spring colour ........................................... 2 off white/green -suffix ‘C’

2 off pigeon blue -suffix ‘A’

4 off ruby red -suffix ‘B’

Clutch release bearing.. ......................................... Ball journal

CLUTCH

Type ................................................................. Borg and Beck diaphragm spring

Centre plate diameter ...........................................

267

mm (10.5 in)

Facing material ................................................... Raybestos 1488-05. Grooved. Whitehiolet

Damper spring colour ........................................... Light blue/dark blue

Release bearing.. ................................................. Ball journal

Number of damper springs.. ................................... 6

GENERAL SPECIFICATION DATA 04

4 ,c:.:

.......

.........

..... ..,, Main gearbox

Type LT77 ......................................................

Speeds ...........................................................

Synchromesh ...................................................

Ratios:

Fifth ...........................................................

Fourth (direct) ..............................................

Third ..........................................................

Second ........................................................

First. ...........................................................

Reverse .......................................................

Single helical constant mesh

5 forward 1 reverse

All forward speeds

0.8314:l

1.0000: 1

1.5074:l

2.3008: 1

3.5850: 1

3.7007:l

...

. .

. . .

Transfer box

Type LT230R ..................................................

Ratios:

. High ...........................................................

Low ............................................................

Overall ratios (final drive):

Fifth ...........................................................

Fourth.. .......................................................

Third ..........................................................

Second ........................................................

First,. ..........................................................

Reverse .......................................................

Input gear .......................................................

Intermediate gear .............................................

Output gear.. ...................................................

Two-speed reduction on main gcarbox output.

Front and rear drive permanently engaged via a lockable differential

1.6670

3.3198

In high transfer

4.9042: 1

5 3987: 1

8.8917: 1

13.5715:l

21.1472:l

21.8293:l

26 Teeth

19 x 41 x 35 Tceth

40 x 37 Teeth

In low transfer

9.7666:l

11.7471 : 1

17.7075: 1

27.0272: 1

42.1138: 1

43.4723:l

....

TRANSMISSION

Main gearbox

Type LT95 ......................................................

Speeds ...........................................................

Synchromesh ...................................................

Ratios:

Fourth (direct) ..............................................

Third ..........................................................

Second ........................................................

First ............................................................

Reverse .......................................................

Single helical constant mesh

4 forward 1 reverse

All forward speeds

1.0000:1

1.5049: 1

2.4480: 1

4.0691 : 1

3.6643:l

, . .

Transfer box

Type LT95 ......................................................

Ratios:

High ...........................................................

Low ............................................................

Overall ratios (final drive):

Fourth.. .......................................................

Third ..........................................................

Second ........................................................

First.. ..........................................................

Reverse .......................................................

Two-speed reduction on main gearbox output.

Front and rear drive permanently engaged via a lockable differential

1.3362

3.3206

In high transfer

4.7281 : 1

7.1 154: 1

11 S74.5: 1

19.2390: 1

27.3250: 1

In low transfer

1 1.7497: 1

17.6822:l

28.7634: 1

47.8101:l

43.0538:l

G E N ERAL SPECIFICATION DATA

TRANSMISSION

Ten VS with 5-speed gearbox

Main gearbox

Type - ..............................................

LT85 5-speed helical constant mesh, with synchromesh on all forward gears

Main gearbox ratios.. .........................................

Fifth (Cruising gear)

Fourth

Third

Second

First

Reverse

0.7951

.oooo

1.4362

2.1804

3.6497

3.8242

Transfer gearbox

Type.. ............................................................

LT230T. Two-speed reduction on main gearbox output.

Front and rear drive permanently engaged via a lockable differential.

........................................... High

Low

........................................ High

Overall ratio (including final drive) -

Low

1.1923

3.3198

1.410

3.3198

In high transfer In low transfer

Fifth (Cruising gear)

Fourth

Third

Second

First

Reverse

3.3544

4.2189

6.0592

9.1989

15.3977

16.1339

9.3401

11.7471

16.8712

25.6134

42.8734

44.9233

Overall ratio (including final drive)

In high transfer In low transfer

Fifth (Cruising gear)

Fourth

Third

Second

First

Reverse

3.9695

4.9925

7.1702

10.8856

18.2210

19.0922

9.3401

11.7471

16.87 12

25.6 134

42.8734

44.9233

REAR AXLE

Type ................................................................. Salisbury 8HA

Ratio ................................................................ 3.538

Track ................................................................

1485,90 mm (58.50 in)

Type..

- models and Ninety rear

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

Spiral bevel, enclosed constant velocity joints

Ratio

................................................................ 3.538

PROPELLER SHAFTS

Type: Front and rear ............................................

Single Hookes universal needle roller joints. Sliding portion on front shaft gaiierea, rear shaft open

GENERAL SPECIFICATION DATA

104

/*:-

:”**

- SUSPENSION

Type .................................................................

Front ................................................................

Rear .................................................................

Coil springs controlled by telescopic dampers front and rear

Transverse location of axle by Panard rod, and fore and aft location by two radius arms

Fore and aft movement inhibited by two tubular trailing links. Lateral location of axle by a centrally positioned ‘A’ bracket bolted at the apex to a ball joint mounting. An optional levelling unit is positioned between the ball joint and upper cross member

BRAKES 2.25 Petrol and V8 Engine

System .............................................................. Direct acting servo assisted dual braking system with

Girling tandem master cylinder and pressure differential warning actuator, combination valve, o r G . valve

Footbrake

Front

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

. Disc diameter ...............................................

Number of pistons per wheel

Total lining area

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

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

Lining material.. ............................................

Rear ..............................................................

Drum diameter .............................................

Total lining area ............................................

Brake drum width.. ........................................

Lining material.. ............................................

Lockheed Disc

300 mm (11.81 in)

232 cm2

Don 230

Girling single cylinder drum brake

280 mm (11 in)

493 cm2

63.9”

Ferodo 2629

Handbrake

Type

Models

.............................................................. Transmission drum brake cable operated

Drum diameter ................................................ 254 mm (10 in)

Lining material.. ............................................... Don 269

BRAKES

System .............................................................. Direct acting servo assisted dual braking system with

Girling tandem master cylinder and pressure differential warning actuator, combination valve, or G . valve.

Servo assistance initiated by an engine driven air evacuation pump and sustained by a vacuum tank

(vacuum tank deleted on 2.5)

Evacuation pump

Maximum speed ...............................................

Oil capacity

5000 rpm. Belt drive

..................................................... 40 cm3 (2.4 in3) SAE 15W-50

Evacuation pump

Maximum speed ...............................................

Lubrication .....................................................

.Minimum vacuum !eve! at 2500 !pn ......................

4000 ‘pm. Gear drive from camshaft

Oil feed via skew gear

0,8 bar

(047

GENERAL SPECIFICATION DATA

STEERING

Type:

Manual - .................................

Manual.. ............................................................

Optional power assisted -

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

Ratios:

Manual Burman straight ahead ...............................

Manual Gemmer .................................................

Power assisted straight ahead. .................................

Number of turns lock to lock:

Manual.. ............................................................

Power assisted .....................................................

Camber angle .....................................................

Castor angle .......................................................

Swivel pin inclination.. ..........................................

Front wheel toe-out - .........

Turning circle between kerbs:

Right-hand drive ..............................................

Left-hand drive ................................................

Steering wheel diameter.. ......................................

Steering damper ..................................................

Track ................................................................

Steering column type ............................................

Burman recirculating ball

Gemmer Hour-glass worm and wheel

Adwest Varamatic

Adwest Lightweight or Gemmer

20,55: 1

20,2: Constant

17.5:l

4.75

3.49

Zero

1,19 - 2,38 mm (A in)

14,O m (45.67 ft)

13,28 m (43.58 ft)

420 mm (16.5 in)

Fitted to drag link

1485,90 mm (58.50 in)

Collapsible coupling

WHEELS AND TYRES

Models

Type of wheel .....................................................

Wheel size. .........................................................

Number of studs ..................................................

Tyre size ............................................................

Ventilated disc

5.50 in F x 16 in

7.50 x 16

ELECTRICAL EQUIPMENT

System .............................................................. 12 volt, negative earth

Battery - litre Petrol and V8 engine

Type:

Lucas -

................................. B.B.M.S. No. 371 Designation

Chloride - standard 9 plate ............................. B.B.M.S. No. 291 190/84/90

Lucas - ...........................

Chloride - .......................

B.B.M.S. No. 389

B.B.M.S. No. 369

Designation

315/120/92

Battery

Type .............................................................. Chloride B.B.M.S. No. 243 15 plate designation 395/175/90

(?:

GENERAL SPECIFICATAION DATA

1041

,.:.;:

,:I

,,,.

Alternator

Type ..............................................................

Maximum D.C. output at 6000 rpm .......................

Rotor - .................................

Stator -

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

New brush length ..............................................

Renew brush at ................................................

Brush spring pressure ........................................

Regulator controlled voltage ...............................

Lucas A115-34

34 amps

3.27 ohms at 20°C

0.138 ohms at 20°C 5 %

20 mm

10 mm

1.3 - 2.7 N (4.7 - 9.8 oz)

13.6 - 14.4 volts measured across battery

Note: From the following engine numbers a 45 amp output alternator is fitted.

12505497C llH05639C llH05629C

Land Rover 90/110 2.5 litre Diesel

Land Rover 90 2.3 litre Petrol

Land Rover 110 2.3 litre Petrol

Alternator

- engine

Type ..............................................................

Maximum D.C. output at 6000 rpm .......................

Rotor -

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

Stator - ...................

New brush length. .............................................

Renew brush at ................................................

Brush spring prcssure ........................................

Regulator controlled voltage ...............................

Lucas A115-45

45 amps

3.2 ohms at 20°C 5 %

0.092 ohms at 20°C f

20 mm

10 mm

1.3 - 2.7 N (4.7 - 9.8

OZ)

13.6 - 14.4 volts measured across battery

Starter motor

Type ..............................................................

Brush spring tension ..........................................

Minimum brush length .......................................

Lucas 2M100

1020 gms (36 02s)

9,s mm (0.375 in)

. .

Starter motor

Type .............................................................. Lucas 2M113

New brush length ..............................................

Renew brush at ................................................

Armature end-float -

Cast aluminium intermediate bracket .................

Pressed steel intermediate bracket .....................

Commutator minimum diameter ..........................

22.2 mm (0.875 in)

8 mm (0.312 in)

0,03 - 1,4 mm (0.001 - 0.056 in)

0,03 - 1,55 mm (0.001 - 0.061 in)

38 mm (1.5 in)

Starter motor

- engine

Type ..............................................................

Brush spring tension ..........................................

Brush minimum length .......................................

Lucas 3M100 pre-engaged

1020 gms (36 ozs)

9,5 mm (0.375 ins)

G E N ERA L S P E C I FICATION DATA

Wiper motor -All Models

Type ..............................................................

Armature end-float

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

Minimum brush length..

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

Lucas 14W uprated two-speed

0 , l - 0,20 mm (0.004

0.008 in)

4,8 mm (0.190 in)

Distributor - All Petrol engines ..............................

I See 'ENGINE TUNING DATA'

Coil

- .......................................

Fuses

Models

Type .............................................................. 12 cartridge fuses of the following values:

Three 10 amp

Six

8 amp

One 12 amp

Two 2.5 amp

Starter motor

Type .............................................................. Paris Rhone D9R91 12 volt

Tyres

6.00-16

CROSS-PLY

7.50-16

CROSS-PLY

205R16

RADIAL-PLY

7.50R16

RADIAL-PLY

7.50-16

CROSS-PLY

750R16

RADIAL-PLY bar

Ibf/in2 kgf/cm2 bar

Ibflin2 kgf/cm2 bar lbf/inZ kgf/cm2 bar

Ibf/in* kgf/cm2 bar

Ibf/in2 kgf/cm2

G EN E RAL SPECIFICATION DATA 04

1 9

2,O

1 9

23-3

1 9

2 8

1 9

2.0

Normal

All load conditions

Front

2.4

2.5

1 9

2,o

Rear

3,25

393

2,4

2.5

2,4

295

2,75

2,8

2,9

3 ,O

373

3.4

Emergency soft

1,1

'1J

191

1.1

191

1,1

191

1,1

Front

1 s

1,1

131

Unladen

Rear

1,1

1.1

1 s

1,1

171

1 s

1.1

1 s

171

1 J

191

171

1.1

191

1,1

1 s

1,1

Front

171

1 J

1.1

Laden

1.8

1,8

125

1.6

1,6

Rear

1.6

1,6

1.6

REPLACEMENT BULBS AND UNITS

...

.....

..,.

Headlamps:

- and Europe (except France) .......................

- France and Algeria ........................................

- Rest of world, right-hand steering

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

- .......................

Front side lamps ..................................................

Side repeater lamps ..............................................

Stopltail lamps ....................................................

Flasher lamps. .....................................................

Number plate lamp

Reverse lamp

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

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

Rear fog guard lamp .............................................

Interior lamp ......................................................

Warning lights .....................................................

Instrument illumination.

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

Hazard switch warning light ...................................

60155 W Halogen bulb

60155 W Halogen bulb, yellow

75150 W Sealed beam unit

60150 W Sealed beam unit

1 2 v 5w

1 2 v 4 w

1 2 v 2115w

1 2 v 21w

1 2 v 4 w

1 2 v 2 1 w

1 2 v 21w

1 2 v 1 2 w

1 2 v 3w

12V 0.6W

1041

GENERAL SPECIFICATION DATA

VEHICLE WEIGHTS AND PAYLOAD

Payload figures quoted in the accompanying table are nominal values for a base specification vehicle and will in general represent the maximum, as any options or extras fitted to the vehicle will increase its unladen weight and hence decrease its allowable payload.

When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken

of

the unladen vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values.

It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither maximum axle loads nor Gross Vehicle Weight are exceeded.

Land Rover Ninety

Model

Gross Vehicle Weight

EEC Kerb Weight

EEC Payload

Unladen Weight

Payload kg

2.5P

Soft Top

2.5D 3.5P 2 3 ’

STANDARD SUSPENSION 2400

1606 1643 1602 1635 kg kg kg

794 757 798

1487 1519 1483

913 881 917

765 728

1516 1548

884

Pick-up

2.5D

1672

852

3.5P 2.5P

1631

769

1512

888

Hard Top

2.5D

1648 1685

752 715

1529 I561

871 839

Station Wagon

3.5P 2.5P 2.5D 3.5P

1644

7Sb

1525

875

1690

710

1571

829

1727 1686

673

1603

797

714

1567

833

Maximum Axle Weights, all Ninety models with Standard Suspension

Front Axle 1200 kg Rear Axle 1380 kg

Gross Vehicle Weight HIGH L O A D SUSPENSION 2550

EEC Kerb Weight kg 1633 1670 1629

EEC Payload

Untaden Weight

Payload kg kg kg

917

880

1514 1546

1036 1004

921

1510

1040

1662

888

1543

1007

1699

851

1575

975

1658

892

1539

1011

1675

875

1556

1712

838

1588

962

1671

879

1522

998

1717 1754

833

1598

952

796

1630

920

1713

837

1594

956

Maximum Axle Weights, all Ninety models with High Load Suspension

Front Axle 1200 kg Rear Axle 1500 kg

Land Rover One Ten

Model

Gross Vehicle Weight

EEC Kerb Weight

EEC Payload

Unladen Weight

Payload

Soft Top Pick-up Hard Top Station Wagon High Capacity Pick-up

2.5P 2.5D 3.5P 2.5P 2.5D 3.5P 2.5P 2.5D 3.5P 2.5P 2.5D 3.51’ 2.5P 2.5D 3.5P

UNLEVELLED SUSPENSION 3050 kg kg kg kg

1723 1742 1698 1724 1743 1699 1777 1796 1752 1887 1906 1862 1813 1859 1778

1327 1308 1352 1326 1307 1351 1273 1254 1298 1163 1144 1188 1237 1191 1272

1588 1599 1563 1589 1600 1564 1642 1653 1617 1752 1763 1727 I678 1716 1643

1462 1451 1487 1461 1450 1486 1408 1397 1433 1298 1287 1323 1372 1334 1407

Maximum Axle Weights, a11 One Ten models with Unlevelled Suspension

Front Axle 1200 kg Rear Axle 1850 kg

Gross Vehicle Wcight 1.EVELLED SUSPENSION 2950

EEC Kerb Weight

EEC Payload

Unladen Weight

Payload kg kg kg kg

1733 1752 1708 1734 1753 1709 1787 1806 1762 1897 I916 1872 1823 1869 1788

1217 1198 1242 1216 1197 1241 1163 1144 1188 1053 1034 1078 1127 1081 1162

1598 1609 1573 1599 1610 1574 1652 1663 1627 1762 1773 1737 1688 1726 16.53

1352 1341 1377 1351 1340 1376 1298 1287 1323 1188 1177 1213 1262 1224 1297

Maximum Axle Weights. all One Ten models with Levelled Suspension

Front Axle 1200 kg Rear Axle 1750

e-<-

\ /

E N G IN E TUNING D A T A

105 I

V8 PETROL ENGINE TUNING DATA

(with 4-speed gearbox and without electronic ignition)

....

. I .

ENGINE

Compression ratio.. ..............................................

Firing order ........................................................

Cylinder numbering system, front to rear:

Left bank ........................................................

Right bank ......................................................

Compression pressure (minimum) ...........................

Timing marks. .....................................................

Valve clearance.. .................................................

Valve timing:

Inlet opens ......................................................

Inlet closes ......................................................

Inlet duration.. .................................................

Inlet peak .......................................................

Exhaust opens.. ................................................

Exhaust closes.. ................................................

Exhaust duration ..............................................

Exhaust peak ...................................................

9.35:l or 8.13:l Dependent upon market

1--&-4-=5-7-2

8 2

9,5 kgf cm2 (135 lbf in')

On crankshaft pulley vibration damper

Not adjustable

36" B.T.D.C.

64" A.B.D.C.

280"

99" A.T.D.C.

74" B.B.D.C.

26" A . T . D . C .

280"

119" B.T.D.C.

CARBURETTERS

Type .................................................................

European Australian .........................................

Other markets -

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

Needle:

Australian .......................................................

Other markets -

-emission

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

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

Idle speed (engine hot):

Australian .......................................................

Other markets - ............................

-emission ..................................

Fast idle speed (engine hot) ....................................

Mixture setting - at idle:

Australian .......................................................

Other markets ..................................................

Two Solex

175 CDSE

175 CD3

BIFH

BIFQ

BIFK

700 - 750 rpm (run-in) 550 - 650 rpm (new engine)

550 - 650 rpm

700 - 750 rpm (run-in) 550 - 650 rpm (new engine)

1050 - 1150 rpm

2% - 3.5% Pulsair connected

1 .WO

IGNITION

Coil makehype ....................................................

Primary resistance at 20°C (68°F) .............................

Consumption, ignition on, at 2000 rpm

Sparking plug type

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

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

Sparking plug gap ................................................

Ignition timing, dynamic or static.. ...........................

Fuel octane rating Australia.. .................................

Non-emission

Emission

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

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

Engine idle speed.. ...............................................

A C Delco with ballast resistor

1.2 - 1.4 ohms

1 amp

Champion N12Y or Unipart GSP131

0,71 - 0,84 mm (0.028 - 0.033 in)

5" to 7"B.T.D.C.

97 RON minimum

90 RON minimum

750 rpm maximum with vacuum pipe disconnected

ENG I N E TU N ING DATA

DISTRIBUTOR

Makehype.

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

Rotation of rotor .................................................

Dwell angle ........................................................

Contact breaker gap .............................................

Condenser capacity ..............................................

Centrifugal advance range and capsule.. ....................

Vacuum advance capsule range ...............................

Vacuum retard capsule range.. ................................

Lucas 35D8

Anti-clockwise

26"

28"

0,35

0,40 mm (0.014

0.016 in)

1"- 3" at 800 rpm

0.18 - 0.25 microfarad

12"-14"at2300rpm 15.03 7"-9"at 1800rpm

1/20

- 4" at 750 rpm

- 4%" at 10 in Hg

-Tat

20

in Hg

5"- 7" at 9 in Hg

7" at 14 in Hg

Emission 2%" - 4W at 10 in Hg

Engines 7" - 9" at 20 in Hg

5"- 7" at 9 in Hg

5"- 7" at 14in Hg

ADR

Emission

Engines

V8 ENGINE TUNING DATA

(Ninety and One Ten V8 with 5-speed gearbox and electronic ignition)

E UROPE

ENGINE

Compression ratio.. ..............................................

V8 cylinder

8.13:l

Valve timing

Opens ............................................................

Valve peak ......................................................

Inlet

30" B .T.D. C.

Closes ............................................................ 75" A.B. D. C.

Duration ......................................................... 285"

112.5" A.T.D.C.

CARBURETTERS

Type ................................................................. 2 x Solex 175 CDSE

Solex specification number.. ................................... 3994

Needle .............................................................. BIFK

Idle speed (engine hot).. ........................................ 700 to 750 revlmin (run-in engine)

Fast idle speed (engine hot) ....................................

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

550 to 650 rev/min (new engine)

1050 to 1150 rev/min

1.5 to 3% Pulsair connected

Exhaust

68" B.B.D.C.

37" A.T.D.C.

285"

105.5" B.T.D.C.

IGNITION

Distributor makehype.. .........................................

Direction of rotation.. ............................. ..: ...........

Centrifugal advance

Decelerating check with vacuum retard pipe disconnected

Engine rev/min

3600. ..............................................................

2400. ..............................................................

1600. ..............................................................

1000.. .............................................................

No advance below 500 rev/min

Ignition timing, dynamic; models with emission control ...............................

Lucas 35 DM8 Electronic (Early Models)

Lucas 35 DLM8 Electronic (Later Models)

Clockwise

Crankshaft angle

22" to 28"

13" to 21"

5" to 9"

0" to 3"

6" B.T.D.C. with vacuum pipes disconnected using 90-93 octane fuel - 2 star rating in UK

< ., ,;

,::7.

: .

. ,

.+.:

ENGINE TUNING D A TA 05

V8 ENGINE TUNING DATA

(Ninety and One Ten V8 with 5-speed gearbox and electronic ignition)

AUSTRALIA

ENGINE V8 cylinder

Compression ratio.. .............................................. 9.35: 1

Valve timing

Opens ............................................................

Inlet

30" B.T.D.C.

Closes ............................................................ 75" A.B .D. C.

Duration ......................................................... 285"

Valve peak ...................................................... 112.5" A.T.D.C.

Exhaust

68" B.B.D.C.

37" A.T.D.C.

285"

105.5" B.T.D.C.

. . .

CARBURETTERS

Type ................................................................. 2 x Solex 175 CDSE

Solex specification number.. ................................... 4104

Needle .............................................................. BIFH

Idle speed (engine hot).. ........................................ 700 to 750 rev/min (run-in engine)

550 to 650 rev/min (new engine)

Fast idle speed (engine hot) ....................................

Mixture setting - ..................................

1050 to 1150 rev/min

2% to 3.5% Pulsair connected

IGNITION

Distributor makehype.. .........................................

Direction of rotation. ............................................

Centrifugal advance

Decelerating check with vacuum retard pipe disconnected

Engine rev/min

2900.. .............................................................

2400. ..............................................................

1600. ..............................................................

No advance below 800 rev/min

Ignition timing ....................................................

Lucas 35 DM8 Electronic (Early Models)

Lucas 35 DLM8 Electronic (Later Models)

Clockwise

Crankshaft angle

12" to 16"

8" to 12"

2" to 6"

6" B.T.D.C. with vacuum pipes disconnected using 96 octane fuel

V8 ENGINE TUNING DATA

(Ninety and One Ten V8 with 5-speed gearbox and electronic ignition)

SAUDI ARABIA

ENGINE

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

Valve timing (low lift camshaft)

Opens ............................................................

Inlet

36" B.T.D.C.

Closes ............................................................

Duratien .........................................................

Valve peak ......................................................

V8 cylinder

64" A.B .D. C.

280"

99" A.T.D.C.

Exhaust

74" B.B.D.C.

26" A.T.D.C.

*-\on0

LDV

119" B.T.D.C.

ENGINE TUNING DATA

CARBURETTERS

Type .................................................................

Solex specification number.. ...................................

Needle ..............................................................

Idle speed (engine hot).. ........................................

Fast idle speed (engine hot) ....................................

Mixture setting - CO at idle ..................................

2 x Solex 175 CDSE

3999

BIFC

700 to 750 rev/min (run-in engine)

550 to 650 rev/min (new engine)

1050 to 1150 rev/min

1.5% to 3% Pulsair connected

IGNITION

Distributor makehype.. .........................................

Direction of rotation.. ...........................................

Centrifugal advance

Decelerating check with vacuum retard pipe disconnected

Engine rev/min

4600. ..............................................................

3600. ..............................................................

3000.. .............................................................

2400., .............................................................

1600.. .............................................................

No advance below 900 rev/min

Ignition timing, dynamic; models with emission control ...............................

Lucas 35 DM8 Electronic (Early Models)

Lucas 35 DLM8 Electronic (Later Models)

Clockwise

Crankshaft angle

21" to 25"

16" to 20"

12" to 16"

7" to 11"

1" to 3"

6" B.T.D.C. with vacuum pipes disconnected using 90-93 octane fuel

V8 ENGINE TUNING DATA

(Ninety and One Ten V8 with 5-speed gearbox and electronic ignition)

ALL COUNTRIES EXCEPT EUROPE, SAUDI ARABIA AND AUSTRALIA

ENGINE V8 cylinder

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

Valve timing (low lift camshaft) Inlet

Opens ............................................................ 36" B.T.D. C.

Closes ............................................................ 64" A.B.D.C.

Duration ......................................................... 280"

Valve peak ...................................................... 99" A.T.D.C.

CARBURETTERS

Type .................................................................

Solex specification number.. ...................................

2 x Solex 175 CDSE

4000

Needle .............................................................. BIFQ

Idle speed (engine hot).. ........................................ 700 to 750 rev/min (run-in engine)

Fast idle speed (engine hot) ....................................

550 to 650 rev/min (new engine)

1050 to 1150 rev/min

Exhaust

74" B.B.D.C.

26" A.T.D.C.

280"

119" B.T.D.C.

ENGINE TUNING DATA

SPARKING PLUGS

8.0:l compression ratio

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

Champion N12Y or Unipart

GSP

131

Gap .................................................................. 0,75-0,80mm (0.029-0.032in)

IGNITION COIL

Makehype.. ........................................................ AC Delco 7992188

Primary resistance at 20°C (68°F) .............................

Consumption - .........

3.0 - 3.5 ohms

2.0 amps approx.

CARBURETTER

Makeltype.. ........................................................ Weber 32/34 DMTL

Venturi .............................................................

Auxiliary Venturi ................................................

Main jet .............................................................

Air correction jet .................................................

Emulsion tube.. ...................................................

Idle jet ..............................................................

Idle CO%

Idle speed

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

- ................................................

Primary

110

160

€30

1% - 2.5%

600 - 700 rpm

Secondary

115

160

F30

2.5 LITRE PETROL ENGINE TUNING DATA

ENGINE

Firing order ........................................................

Compression pressure (approximately): ....................

Ignition timing dynamic @ 2000 rpm ........................

Static, if no dynamic equipment available ..................

Timing marks. .....................................................

Valve clearance, inlet and exhaust ...........................

Valve timing:

Inlet opens ......................................................

Inlet closes ......................................................

Inlet peak .......................................................

Exhaust opens.. ................................................

Exhaust closes.. ................................................

Exhaust peak ...................................................

1-3-4-2

11,2 kgf cm2 (160 Ibf in2) @ 300 rpm cranking speed

16" B.T.D.C. using

T.D.C.

90 octane fuel with vacuum pipe disconnected

On crankshaft pulley

0,25 mm (0.010 in) Engine hot

11" B.T.D.C.

47"A.B.D.C.

108" A.T.D.C.

46" B.B.D.C.

18" A.T.D.C.

104" B.T.D.C.

With a 0,38 mm (0.015 in) valve clearance.

Nominal setting for checking only.

DISTRIBUTOR

Type .................................................................

Rotation of rotor .................................................

Contact breaker gap .............................................

Dwell angle ........................................................

Centrifugal advance range .....................................

., vacuum advance capsuie range ...............................

Lucas 45D4

Anti-clockwise

0,35 - 0,40 mm (0.014 - 0.016 in)

49" - 59"

0" - 1" at 500 Distributor rpm

18" - 20" at 2250 Distributor rpm

0" - M" at 3.5 Hg

11" - 13" at 25 Hg

'1.

ENGINE TUNING DATA

105

?::'.,

, . . * - . I .

.". ::i

SPARKING PLUGS

8.0: 1 compression ratio .........................................

Champion N9YC

Gap .................................................................. 0,72 - 0 3 8 mm (0.028

0.035 in)

IGNITION COIL

Makehype ..........................................................

Primary resistance at 20°C (68°F) .............................

Consumption -

Bosch 0221 119 368

2.9 ohms

......... 2.0 amps approx.

CARBURETTER

Makehype. ......................................................... Weber 32/34 DMTL

Needle valve.. ..................................................... 175

-.:

.....

Venturi .............................................................

Auxiliary Venturi ................................................

Main jet .............................................................

Air correction jet .................................................

Emulsion tube.. ...................................................

Idle jet ..............................................................

Idle CO% ..........................................................

Idle speed

- - ...............

Idle speed

- - .....................

Float level ..........................................................

Primary

112

160

F30

1.5% k 1%

700 rpm

800 rpm k 50 rpm

7 k mm (0.275 iz 0.019 in)

Secondary

112

190

F39

. . .

......,

2.25 and 2.5 LITRE DIESEL ENGINE TUNING DATA

ENGINE

Firing order ........................................................

Injection timing.. .................................................

Timing marks:

Valve timing ....................................................

Injection timing. ...............................................

Valve clearance inlet and exhaust .........................

Valve timing:

Inlet opens ......................................................

Inlet closes ......................................................

Inlet peak .......................................................

Exhaust opens.. ................................................

Exhaust closes.. ................................................

Exhaust peak ...................................................

Low idle speed .................................................

High idle speed ................................................

1-3--4---2

13" B.T.D.C. (2.25 litre Diesel)

On engine flywheel and damper on 2.5 Diesel

On engine flywheel and pump flange

0,25 mm (0.010 in)

16" B.T.D.C.

42" A.B.D.C.

103" A.T.D.C.

5l"B.B.D.C.

13" A.T.D.C.

109" B.T.D.C.

650 5 20 rpm

4200 +- 20 rpm

INJECTORS

Makehype.. ........................................................ CAV Pintaux

Nozzle size ......................................................... BDNO/SPC 6209 or BDNO/SP 6209

Opening pressure.. ............................................... 135 Atm

ENGINE TUNING DATA

HEATER

PLUGS

Makelt ype .......................................................... Probe type, Champion CH 63 12 volt

DISTRIBUTOR

PUMP

Makehype. .........................................................

Direction of rotation.. ...........................................

Maximum speed setting (sealed) 2.25 engine ..............

Maximum speed setting (sealed) 2.50 engine ..............

Back leakage rate 150 - 100 Atm:

New nozzle ......................................................

Original nozzle.. ...............................................

CAV DPA-2.25 DPS-2.50 type with mechanical governor and auto advance and solenoid electrical shut-off

Clockwise, viewed from drive end

4200 engine rpm

4400 k rpm

7 seconds

5 seconds

. fi

':I

TORQUE WRENCH SETTINGS

ENGINE litre Petrol and Diesel

Bearing in water pump casing .................................

Breather filter to top cover .....................................

By-pass housing to thermostat housing ......................

Carburetter to inlet manifold ..................................

Chainwheel pulley to camshaft ................................

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

Connecting rod t o cap ...........................................

Fan assembly to water pump hub .............................

Fly wheel to crankshaft .........................................

Fuel pump to side cover .........................................

Heat shield bracket to manifold ...............................

Heat shield to bracket ...........................................

Oil strainer to mounting bracket ..............................

P . clip to lifting bracket .........................................

. Plug to immersion heater tapping

Oil pump cover to pump body

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

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

Rocker shaft to pedestal ........................................

Solenoid heat shield to manifold heat shield ...............

Starter motor to housing ........................................

Sump plug to sump ...............................................

Distributor clamp ................................................

Distributor to adaptor ...........................................

Pulley to crankshaft ..............................................

Water temperature to cylinder head adaptor ..............

Spark plug ..........................................................

Adaptor for water temperature transmitter to cylinder head ...................................................

Cover thermostat housing t o cylinder head ................

Lifting bracket to cylinder head ...............................

Rocker pedestal to cylinder head .............................

Top cover to cylinder head .....................................

Alternator adjusting link to cylinder block .................

Alternator mounting bracket to cylinder block ............

Camshaft thrust plate to cylinder block .....................

Chain damper to cylinder block ...............................

Cylinder head (Diesel) to cylinder block ....................

Cylinder head (Petrol) to cylinder block ....................

DPA injector pump (Diesel) to cylinder block ............

Distributor housing (Petrol) to cylinder block .............

Drive shafdgear to cylinder block ............................

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

Flywheel housing to cylinder block ...........................

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

Main bearing cap (Diesel) to cylinder block ...............

Main bearing cap (Petrol) to cylinder block ................

Oil feed pipe to cylinder block ................................

Oil filter t o cylinder block ......................................

Oil pump to cylinder block .....................................

Plug oil gallery front to cylinder block .......................

Plug oil gallery rear to cylinder block ........................

Side cover to cylinder block ....................................

Side cover FP mounting t o cylinder block ..................

Sump to cylinder block (bolts and nuts) .....................

Water pump to cylinder block .................................

Dipstick tube assembly to cylinder block ...................

20 .

22 .

30 .

13 .

7 .

260 .

14 18

14 .

22 .

27 .

22 .

7 .

115 .

91 .

22 .

10 .

80 .

40 .

22 .

130

130 .

20 .

40 .

22 .

30 .

22 .

15 .

22 .

7 .

22 .

40 .

30 .

37 .

22 .

130 .

22 .

7 .

20 .

16 .

20 .

16 .

6 - 8

16 .

5 .

84.8 .

67 .

16 .

7.4 .

59 .

30 .

96 .

14.7 .

30 .

22 .

16 .

11 .

16 .

Ibf ft

16 .

30 .

22 .

27 .

16 .

96 .

14.7 .

16 .

14.7 .

14.7

16 .

30 .

22 .

9.5 .

192

10.3 .

TO R QUE W RE N C H SETTINGS

ENGINE

DPS pump studs to front cover ................................

DPS pump to front cover .......................................

DPS pump to support bracket .................................

Pulley to DPS pump .............................................

Distributor pipe banjo bolts

Tensioner assembly

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

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

Vacuum pump ....................................................

Oil squirt to cylinder block .....................................

Throttle linkage to DPS pump ................................

Throttle bracket to DPS pump ................................

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

Front cover plate to cylinder block ...........................

Cover plate to front cover plate ...............................

Timing pointer to front cover

Drain plate to front cover

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

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

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

. ENGINE

Air intake adaptor to carbs

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

Alternator mounting bracket o cylinder head ............

Alternator to mounting bracket ...............................

Alternator to adjusting link ....................................

Chainwheel to camshaft ........................................

Connecting rod bolt ..............................................

Clutch attachment to flywheel .................................

Cylinder head:

Outer row .......................................................

Centre row ......................................................

Inner row ........................................................

Distributor clamp bolt ...........................................

Exhaust manifold to cylinder heads ..........................

Fan attachment ...................................................

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

Inlet manifold to cylinder heads ..............................

Lifting eye to cylinder heads., .................................

Main bearing cap bolts ..........................................

Main bearing cap rear bolts ....................................

Manifold gasket clamp bolt ....................................

Oil pump cover to timing cover ...............................

Oil plug .............................................................

Oil relief valve cap ...............................................

Oil sump drain plug ..............................................

Oil sump to cylinder block .....................................

Oil sump rear to cylinder block ...............................

Rocker cover to cylinder head .................................

Rocker shaft bracket to cylinder head .......................

Spark plug ..........................................................

Starter motor attachment .......................................

Damper to crankshaft ...........................................

Timing cover to cylinder block ................................

Tempatrol unit to water pump ................................

X$Im+

--- a L G i

---.--

L I I I I I I I ~

* -

- - . l : - A - - . L -

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

-.I c;yllIlUCl UlOLK

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

47 .

24 .

88 .

19 .

74 .

68 .

88 .

5 .

11 .

25 .

40, 6 .

8 - 1 1

17, 6 . 3

13, 8 .

40, 6 . 4

257 .

24 .

36 .

30

6 - 1 0

22 .

42 .

14 20

14 .

5 - 7

22 .

7 - 10

CLUTCH .

Clutch cover bolts ................................................

Slave cylinder bolts ..............................................

27. 5

35 .

18 .

40 .

65 .

1 4 - 16

14- 16

55 .

35 .

50 .

65 .

10 .

8.10

18 .

30 .

5 - 8

13 .

25 .

1 0 - 12

30 .

190 .

18 .

27 30

18 . lbf ft

20 lbf ft

4.5 .

16 .

31 .

10.3 .

16 .

10.3 .

4 - 5

16 .

5 . g

. . . .

.....

;

...

CLUTCH

Clutch cover bolts ................................................

30 . v

MAIN GEARBOX (FIVE-SPEED) LT 77 mm

4-cylinder Petrol and Diesel engine

Oil pump body to extension case .............................

Clip to clutch release lever .....................................

Attachment plate to gearcase ..................................

Attachment plate to remote housing .........................

Extension case to gearcase .....................................

Pivot plate ..........................................................

Remote selector housing to extension case .................

Gear lever housing to remote housing .......................

Guide clutch release sleeve ....................................

Slave cylinder to clutch housing ...............................

Front cover to gearcase

5th support bracket

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

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

Plunger housing to remote housing ..........................

Blanking plug extension case ..................................

:':

Gear lever retainer ...............................................

Yoke to selector shaft ...........................................

Fixing gear lever assembly nut ................................

Reverse pin to centre plate nut ................................

Clutch housing to gearbox bolt. ...............................

Plug -

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

Oil drain plug .......................................................

Oil filter plug

Plug oil filler

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

- ..............................

Breather ............................................................

Oil level plug ......................................................

Blanking plug - ........................

Fifth gear layshaft nut ...........................................

7 .

7 - 10

7 10

22 .

7 - 10

22 .

40 .

65 .

22 .

25 .

25 35

25 .

7 - 11

25 .

20 .

204 .

.I.

....

...

MAIN GEARBOX (FIVE-SPEED) LT85 .

V8 engine

Stop . ..................................

Clip to clutch releasc lever .....................................

Spring housing to top cover ....................................

Plate . ..................

Slave cylinder t o clutch housing ...............................

5th fork bracket ...................................................

Front cover to bearing plate ...................................

Plate - ................................

Selector fork to shaft and reverse beam to shaft ...........

Top cover to gearbox ............................................ lst/2nd selector fork to shaft ...................................

Extension case to gearbox ......................................

Extension case t o gearbox ......................................

Clutch housinghearing plate/gearbox

Layshaft

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

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

Reverse lever pivot ..............................................

Gross hole/gearbox casing ......................................

Filler/top cover ....................................................

Oil leveygear case ................................................

Filter plug

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

Drain plug ..........................................................

Reverse light switch hole-blanking plug .....................

Switch reverse light (optional) ................................

47 .

65 .

204 .

65 .

13, 5 .

25 .

65 .

25 .

1 3 3 .

13, 5 .

7 - 10

22 .

30 .

47 .

TORQUE WRENCH SETTINGS

Ibf ft

22 .

5 - 7

16 .21

5 - 7

16 .21

30 .35

35 .40

48 .59

16 .21

19 .26

5 - 8

19 .26

15 .20

130 .170

5 - 7

16- 21

16 .21

16 .

35 .

48 .

150 .170

48 .

I0 .

19 .

48 .

19 .

10- 15

1061

TORQUE WRENCH SETTINGS

TRANSFER BOX LT230R

4-cylinder Petrol and Diesel engine

Pinch bolt, operating arm ......................................

Gate plate to grommet plate ...................................

End cover ..........................................................

Speedometer cable retainer ....................................

Speedometer housinghear output ............................

Locating plate to gear change housing .......................

Bottom cover t o transfer case .................................

Front output housing to transfer case ........................

Cross shaft housing to front output housing ................

Gear change housing ............................................

Pivot shaft ..........................................................

Connecting rod ...................................................

Retaining plate intermediate shaft ...........................

Front output housing cover ....................................

Gear change housing ............................................

Bracket to extension housing ..................................

Finger housing to front output housing ......................

Mainshaft bearing housing .....................................

Brake drum ...............................

Gearbox to transfer box ........................................

Bearing housing to transfer gearbox .........................

Speedometer housing to transfer gearbox ..................

Selector fork to cross shaft .....................................

Yoke to selector shaft high/low ...............................

Selector fork high/low to shaft .................................

Operating arm high/low .........................................

Transmission brake ..............................................

Gearbox to transfer case ........................................

Oil drain plug ......................................................

Differential case ..................................................

Output flange .....................................................

Differential case rear and shaft main drive

214-wheel drive .................................................

Link arm and cross shaft lever to ball joint .................

Oil filler/level plug ...............................................

Transfer breather .................................................

66 .

8 - 12

7 - 11

7 - 10

See note

5 - 7

22 .

40 .

22 .

65 .

See note

25 .

55 .

146 .

Ibf ft

5 - 7

4 - 5

16 .

16 1

16 .

29 .

16 .

48 .

29 .

40 .

108 .

50 .

6 - 9

19 .

5 - 8

NOTE:- Studs to be assembled into casings with sufficient torque to wind them fully home. but this torque must not exceed the maximum figure quoted for the associated nut on final assembly .

TRANSFER GEARBOX LT230T .

4 cylinder Petrol and Diesel engine and VS

Fixings securing mounting brackets to gearbox ...........

Pinch bolt operating arm .......................................

Gate plate to grommet plate ...................................

Bearing housing to transfer case ..............................

Speedometer cable retainer .................................... speedometer housing ...........................................

Locating plate to gear change .................................

Bottom cover to transfer ........................................

Front output housing to transfer ..............................

80 .

7 - 10

See note

5 - 7

22 .

59 .

5 - 7

4 - 5

16 .

TORQU E W REN C H SETTINGS

TRANSFER GEARBOX LT230T

4 cylinder Petrol and Diesel engine and V8 (cont.)

Cross shaft housing to front output housing ................

Gcar change .......................................................

Gear change ........................................................

Cross shaft to highAow lever ...................................

Pivot shaft to link arm ...........................................

Connecting rod ...................................................

Anti-rotation plate intermediate shaft .......................

Front output housing cover ....................................

Pivot bracket to extension housing ...........................

Finger housing to front output housing ......................

Mainshaft bearing housing to transfer case .................

Brake drum to coupling flange ................................

Gearbox to transfer case ...............

Gearbox to transfer case ........................................

End cover bearing housing to transfer case .................

Speedometer housing to transfer .............................

Selector finger to cross shaft (highhow) .....................

Selector fork high/low to shaft .................................

Transmission brake to speedometer housing

Transfer case assembly ..............

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

Gearbox to transfer case ........................................

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

Oil drain plug ......................................................

Detent plug ........................................................

Differential casings ..............................................

Front and rear out flange .......................................

Differential case rear ............................................

Oil filler and level plug transfer ...............................

Transfer breather .................................................

Inter shaft stake nut ..............................................

22 .

22 . lbf ft

16 .

16 . 22 .

22 .

40 .

40 50

40 50

40 50

22 .

65 .

40 .

16 .

29 .

16 .

48 .

29 .

See note

25 . 19 .

Plug to be coated with Hylomar and peened .

Screw plug fully in (spring solid) then turn two complete turns back .

40 . 55 .

146 .

66 .

25 .

7 - 11

108 .

50 .

19 .

5 - 8

130 . 96 .

NOTE:- Studs to be assembled into casings with sufficient torque to wind them fully home. but this torque must not exceed the maximum figure quoted for the associated nut on final assembly .

GEARBOX AND TRANSFER BOX LT95 .

Bell housing to cylinder block bolts ..........................

Gearbox casing to bell housing 2 off .........................

36, 6 .

1 4 6 3 .

Gearbox casing to bell housing 2 off .........................

Gearbox casing to bell housing nuts ..........................

85, 4 .

Gearbox casing to bcll housing stud and nuts .............. 146, 5 .

Output flange - rear - ....................... 43, 4 .

Output shaft - rear - ..................................... 146, 5 .

Output shaft - - .................................... 146, 5 .

Gear selector spherical scat bolts ............................. 13, 6 .

Propeller shaft to flange bolts ................................. 43, 4 . 5

All other nuts and bolts:

M6 ................................................................

M8 ................................................................

M10 ...............................................................

9, 9 .

23:7 .

48 .

27 .

108 .

63 .

108 .

32 .

108 .

10- 12

32 .

7.3 .

17.5 .

35.4 .

I06 I

T O R Q U E W RE N C H SETTINGS

FRONT AXLE

Hub driving member to hub

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

Brake disc to hub .................................................

Stub axle to swivel pin housing

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

Brake caliper to swivel pin housing ..........................

Upper swivel pin to swivel pin housing

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

Lower swivel pin to swivel

housing

Oil seal retainer to swivel pin housing

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

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

Swivel bearing housing to axle case

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

Pinion housing to axle case .....................................

Crown wheel to differential case ..............................

Differential bearing cap to pinion housing .................

U/J flange to prop shaft .........................................

Mudshield to swivel pin housing

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

Bevel pinion nut ..................................................

60-70

65 .

60 .

120 .

60 .

22 .

7 - 10

65 .

36 .

55 .

80 .

41 - 5 2

7 - 10

95 .

REAR AXLE AND FINAL DRIVE

Crown wheel to differential case ..............................

Rear cover to axle case ..........................................

Ball joint mounting bracket to axle case ....................

U1J flange to prop shaft .........................................

Drum to hub .......................................................

Rear brake assembly and stub axle rear to axle case .....

Hub driving member to hub ...................................

150 .

20 .

125 .

41 .

15 .

60 .

PROPELLER SHAFTS

Coupling flange bolts

............................................ 43 - 51

REAR SUSPENSION

Bottom link to chassis nut ......................................

Bottom link to mounting rubber nuts ........................

Top link bracket to chassis nuts ...............................

Bump stop rubber bracket nuts ...............................

Shock absorber bracket to chassis nuts ......................

Shock absorber upper attachment to bracket ..............

Anti roll bar bush to chassis nuts ..............................

Upper link ball joint to axle castle nut .......................

Anti roll bar ball joint castle nut ..............................

Shock absorber lower attachment nuts ......................

176

40

STEERING AND FRONT SUSPENSION

Tie bar to mounting arm nut ...................................

Mounting arm to chassis nuts ..................................

Tie bar to steering box nuts ....................................

Panard rod to mounting arm nut ..............................

Panard rod to anchor bracket nut .............................

Panard rod mounting bracket to chassis bolts ..............

Drop arm to drag link castle nut

Steering damper to drag link nut

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

Drop arm to steering box nut

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

Radius arm to axle nuts .........................................

Steering box to chassis nuts

Radius arms to chassis nuts

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

Track rod ciamp boit nuts

Drag link clamp bolt nuts

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

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

Steering wheel retaining nut ...................................

Road wheel nuts

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

Ball joint nuts .....................................................

Collapsible coupling nuts ......................................

176

108

176

115 .

176

130

111 .

15 .

92 .

30 .

11 .

44- 52

44 .

32 .

Ibf ft

44 .

44- 52

88 .

44 .

16 .

5 - 7

48 .

26 .

40 .

54 .

30 .

5 - 7

70 .

130

85 .

130

33 t k-

...

($??;

BRAKES

Brake disc to hub

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

Brake caliper to swivel housing ...............................

65 80

120 .

Brake pipe connections to:

P.D.W.A. valve

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

9 - 11

Servo, primary port ........................................... 9 .

Servo. secondary port ........................................ 20 .

Jump hose

- ........................................ 11 . 5

Wheel cylinders ................................................ 6. 8 . 5

ELECTRICAL EQUIPMENT

Alternator:

Shaft nut .........................................................

Through bolts ..................................................

Rectifier bolts ..................................................

Starter motor to engine bolts ..................................

Starter motor:

Through bolts ..................................................

Solenoid fixing stud nut ......................................

Solenoid upper terminal nut ................................

Reverse light switch ..............................................

27. 2 .

4. 5 6. 2

3. 4 .

40. 6 . 4

10. 8

20 .

Lucas 35 DM8 Electronic ignition distributor V8 engine

Pick up bearing plate support pillars ......................... 1 . .

Pickupbarrelnuts ............................................... 1.1 -1.5

...

ELECTRICAL EQUIPMENT . and Diesel engine

Alternator:

Shaft nut .........................................................

Through bolts ..................................................

Rectifier bolts ..................................................

Heater plugs - Diesel ..........................................

Starter motor to engine .........................................

Petrol models:

Starter through bolts ..........................................

Diesel models:

Solenoid to starter nuts ......................................

Solenoid outer terminal nuts ................................

Starter yoke terminal outer nut

Starter through bolts

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

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

Starter earth stud nut .........................................

Eccentric pivot pin locknut

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

27. 2 . 5

4. 5

3. 4

15 .

40 .

10. 8

TORQUE WRENCH SETTINGS

48

88 .

7 - 8

15 .

8 -1 0

5 - 7

20 .

3.3 .

2.5 .

30 .

8.0

4.5

3.0

15 .

9 - 1 1

10 .

4.5

1.5

20 .

3.3 .

2.5 .

11 -22

G ENERAL F I ~ I N G 07

GENERAL FITTING INSTRUCTIONS

PRECAUTIONS AGAINST DAMAGE

1. Always fit covers to protect wings before commencing work in engine compartment.

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

3. Avoid spilling hydraulic fluid or battery 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 satisfactory equivalent, where specified.

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

SAFETY PRECAUTIONS

Whenever possible use a ramp or pit when working beneath vehicle, in preference to jacking. Chock wheels as well as applying hand brake.

Never rely on a jack alone to support vehicle. Use axle stands or blocks carefully placed at jacking points to provide rigid location.

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

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

5. Inspect power leads of any mains electrical equipment for damage and check that it is properly earthed.

6 . Disconnect earth (grounded) terminal of vehicle

7. battery.

Do not disconnect any pipes in air conditioning refrigeration system, if fitted, unless trained and instructed to d o so. A refrigerant is used which can cause blindness if allowed to contact eyes.

8.

Ensure that adequate ventilation is provided when volatile degreasing agents are being used.

WARNING: Fume extraction equipment must be in operation when trachloride, methylene chloride, chloroform or perchlorethylene are used for cleaning purposes.

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

10. Do not leave tools, equipment, spilt oil etc.,

11. around or on work area.

Wear protective overalls and use barrier creams when necessary.

PREPARATION

1. Before removing a component, clean it and its surrounding areas as thoroughly as possible.

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

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

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

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

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

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

DISMANTLING

1. Observe scrupulous cleanliness when dismantling components, particularly when brake, fuel or hydraulic system parts are being worked on. A

2. particle of dirt or a cloth fragment could cause a dangerous malfunction if trapped in these systems.

Blow out all tapped holes, crevices, oilways and

3. fluid passages with an air line. Ensure that any

0-rings used for sealing are correctly replaced or renewed, if disturbed.

Mark mating parts to ensure that they are replaced as dismantled. Whenever possible use marking ink, which avoids possibilities of distortion or initiation of cracks, liable if centre punch or scriber are used.

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

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

6. rebuild.

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

1051

GENERAL FITTING INSTRUCTIONS

INSPECTION

1. Never inspect a component for wear or dimensional check unless it is absolutely clean; a slight smear of grease can conceal an incipient failure.

2. When a component is to be checked dimensionally against figures quoted for it, use correct equipment

(surface plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift checking equipment can be dangerous.

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

4. Use ‘Plastigauge’ 12 Type PG-1 for checking bearing surface clearances; directions for its use, and a scale giving bearing clearances in 0,0025 mm

(0.0001 in) steps are provided with it.

9. When fitting bearing to shaft, apply force only to inner ring of bearing, and only to outer ring when fitting into housing.

ST1042M

BALL AND ROLLER BEARINGS

NEVER REPLACE A BALL OR ROLLER

BEARING WITHOUT FIRST ENSURING T H A T

IT IS IN AS-NEW CONDITION.

1. Remove all traces of lubricant from bearing under inspection by washing in petrol or a suitable degreaser; maintain absolute cleanliness throughout operations.

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

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

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

5. Lubricate bearing generously with lubricant appropriate to installation.

6 . Inspect shaft and bearing housing for discolouration or other marking suggesting that movement has taken place between bearing and seatings. (This is particularly to be expected if related markings were found in operation 2.) If markings are found, use ‘Loctite’ in installation of replacement bearing.

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

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

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

11. Always mark components

ST 1 038 f a of separable bearings

+--*

(e.g. taper roller bearings) in dismantling, to ensure correct reassembly. Never fit new rollers in a used cup.

OIL SEALS

1. Always fit new oil seals when rebuilding an assembly. It is not physically possible to replace a seal exactly when it has bedded down.

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

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

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

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

&*:

%L;’

WLJ

GENERAL FITTING INSTRUCTIONS

10711

. I

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

ST1037M

7. If correct service tool is not available, use a suitable drift approximately 0,4 mm (0.015 in) smaller than outside diameter of seal. Use a hammer VERY

GENTLY on drift if a press is not suitable.

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

NOTE: Most cases of failure or leakage of oil seals are due to careless fitting, and resulting damage to both seals and sealing surfaces. Care in fitting is essential if good results are to be obtained.

JOINTS AND JOINT FACES

1. Always use correct gaskets where they are spccificd.

2. Use jointing compound only when recommended.

Otherwise fit joints dry.

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

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

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

6 . Blow out any pipes, channels or crevices with compressed air, renewing any 0-rings or seals displaced by air blast.

FLEXIBLE HYDRAULIC PIPES, HOSES

1. Before removing any brake or power steering hose, clean end fittings and area surrounding them as thoroughly as possible.

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

3.

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

Reject any hose found faulty.

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

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

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

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

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

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

METRIC BOLT IDENTIFICATION

1. An I S 0 metric bolt or screw, made of steel and larger than 6 mm in diameter can be identified by either of the symbols I S 0 M or M embossed or indented on top of the head.

2. In addition to marks to identify the manufacture, the head is also marked with symbols to indicate the strength grade e.g. 8.8, 10.9, 12.9 or 14.9, where the first figure gives the minimum tensile strength of the bolt material in tens of kg/sq mm.

3. Zinc plated I S 0 metric bolts and nuts are chromate passivated, a greenish-khaki to gold-bronze colour.

ST1035M

1071

GENERAL FIITING INSTRUCTIONS

METRIC NUT IDENTIFICATION

1. A nut with an

I S 0

metric thread is marked on one face or on one of the flats of the hexagon with the strength grade symbol 8 , 1 2 or 14. Some nuts with a strength 4, 5 or 6 are also marked and some have the metric symbol M on the flat opposite the

2 strength grade marking.

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

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

ST1033M

~ ~

_ _

STl036M

HYDRAULIC FITTINGS

WARNING: Metric and Unified threaded hydraulic parts. Although pipe connections to brake system units incorporate threads of metric form, those for power assisted steering are of UNF type. It is vitally important that these two thread forms are not confused, and careful study should be made of the following notes.

Metric threads and metric sizes are being introduced into motor vehicle manufacture and some duplication of parts must be expected. Although standardisation must in the long run be good, it would be wrong not to give warning of the dangers that exist while UNF and metric threaded hydraulic parts continue together in service. Fitting UNF pipe nuts into metric ports and vice-versa should not happen, but experience of the change from BSF to UNF indicated that there is no certainty in relying upon the difference in thread size when safety is involved.

To provide permanent identification of metric parts is

easy

hut recognitinn has been assistpd h\r following means. (Illustration A Metric, B Unified.) the

All

metric pipe nuts, hose ends, unions and bleed screws are coloured black.

2. The hexagon area of pipe nuts is indented with the

3.

letter 'M'.

Metric and UNF pipe nuts are slightly different in shape.

2 m

ST1034M

The metric female nut is always used with a trumpet flared pipe and the metric male nut is always used with a convex flared pipe.

4. AI1 metric ports in cylinders and calipers have no counterbores, but unfortunately a few cylinders with UNF threads also have no counterbore. The situation is, all ports with counterbores are UNF, but ports not counterbored are most likely to be metric.

5. The colour of the protective plugs in hydraulic ports indicates the size and the type of the threads, but the function of the plugs is protcctive and not designed as positive identification. In production it is difficult to use the wrong plug but human error must be taken into account.

The Plug colours and thread sizes are:

UNF

R E D

GREEN i i n x 2 4 U N F

6 x 20 UNF

YELLOW 4 in x 20 UNF

PINK B in x 18 U N F c -

METRIC

BLACK 1Ox 1 mm

GREY 1 2 x 1 mm

BROWN 14 x 1,5 mm

6. Hose ends differ slightly between metric and UNF.

Gaskets are not used with metric hoses. The UNF hose is sealed on the cylinder or caliper face by a copper gasket by the metric hose seals against the bottom of the port and there is a gap between faces of the hose and cylinder.

Pipe sizes for UNF are & in, in and & in outside diameter.

. . 4,75 mm, 6 mm and 8 mm.

4,75 mm pipe is exactly the same as

+ in pipe.

6 mm pipe is 0.014 in smaller than i in pipe. 8 mm pipe is 0.002 in larger than & in pipe.

Convex pipe flares are shaped differently for metric sizes and when making pipes for metric equipment, metric pipe flaring tools must be used. f

GENERAL FITTING INSTRUCTIONS

ST1032M

The greatest danger lies with the confusion of

10 mm and

2 in UNF pipe nuts used for in (or

4,75 mm) pipe. The

3 in UNF pipe nut or hose can be screwed into a 10 mm port but is very slack and easily stripped. The thread engagement is very weak and cannot provide an adequate seal.

The opposite condition, a 10 mm nut in a in port, is difficult and unlikely to cause trouble. The 10 mm nut will screw in 1; or 2 turns and seize. It has a crossed thread ‘feel’ and it is impossible to force the nut far enough to seal the pipe. With female pipe nuts the position is of course reversed.

The other combinations are so different that there is no danger of confusion.

- -

,’

KEYS AND KEYWAYS

1. Remove burrs from edges of keyways with a fine file and clean thoroughly before attempting to refit key.

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

7 :

...

TAB WASHERS

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

Always renew a used tab washer.

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

SPLIT PINS

1. Fit new split pins throughout when replacing any unit.

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

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

ST1030M

NUTS

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

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

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

LOCKING WIRE

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

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

SCREW THREADS

1. Both UNF and Metric threads to I S 0 standards are used. See below for thread identification.

2. Damaged thrcads must always be discarded.

Cleaning up threads with a die or tap impairs the strength and closeness of fit of the threads and is not recommcndcd.

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

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

5 . Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads

can

affect the torque reading.

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

7. Always oil thread lightly before tightening to ensure a free running thread, except in the case of self-locking nuts.

1071

GENERAL FITTING INSTRUCTIONS

UNIFIED THREAD IDENTIFICATION

1. Bolts

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

2. Nuts

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

3. nut.

Studs, Brake Rods, etc.

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

ST1039M

‘2

. .

COMPONENTS

Engine V8

Carburetter

Dashpots

Engine

4-cyl. pctrol

Engine

4-cyl. diesel

'LT77-five- speed gearbox

'LT95

- speedgearbox including transfer box

Front differential

Rear differential jwivel pin iousings and

-R30R

LT23OT rransfer box

2T85 -five-

,peed gearbox

/8 cylinder

:rant and rear lteering box

Manual)

'ower steering s applicable iir cleaner

-cyl. petrol i r cleaner

-cyl. diesel rake and clutch reservoirs

Lubrication nipples

(hubs, ball joints, etc.)

plus

15Wi40 o r

Eurotex

Motor Oil t o w n 0

3ils lisled on lines marked (*) may

Duckhams

Q-Matic

Tvoe G

Duckhams

15W/50

Hypergrade

Motor Oil

Esso

Superlube

(15W140)

Mobil

Super

IOW140

Duckhams

Hypoid 90 so be used in

LTZ!

Esso

Gear Oil

35w/90 transfer box.

Mobil

Mobilube

H D W

Fina

Supergrade

Motor Oil

10W/40 or

15w/40

Fina

Pontonic MP

ISAEXOW/90

Shell Super Havoline

Motor Oil

15W/40 or

1 OW/40

Motor Oil

1SW140 or

Eurotex HD

Shell

I IOW/30

Texaco

Multigear

Lubricant

E P 85W190

3P Visco

!Ooo

Visco

(ova

10W/40)

-2

Gear

#AB

Oil

90EP

DX 2D

UP Visco

(15W/40)or

ß P Visco

(IOW130)

BP Visco

(15W/40) or

BP Visco

Castrol

GTX

(15W/50)

Castrol

LM Grease

Castrol

HYPOY

SAE 90EP

Castrol

T O Dexron IID

Castrol GTX

(15W/5!)or

Castrolite

(

10 W/40)

Castrol GTX

(15W150)

Castrolitc

( I Uw140) or

Duckhams

Hypergrade

15W/50

Duckhams

Hypoid

Duckhams

Fleetmatic C D or

Duckhams

D-Matic

Duckhams

I5W/50

Hypergrade

Motor Oil

Mobil Fina Shell Esso

Superlube

15W/40

Super

10w/40

Supergrade

Motor Oil

10W/40 or 15w/40

Havoline

Motor Oil

15 or

W/40

Esso

Multi- purposc

Grease

Esso

Gear Oil s5w/90

Y;;

Dexron IID

Esso

Superlube

(15W/40)

I -

Mobil-

Mobil

Mobilube

HD9U

Mobil

ATF 220

Mobil

Super

15W/40 or 1OW/40

15W/40

Fina

Pontonic MP

/SAESOW/9O

Fina

Dexron IID

Fina

Supergrade

Motor Oil

15W/40or

10W/40

I 1%;;

1 o r

10W/40

Shell

ATF

Dexron IID

Shell Super

Motor Oil

15W/40or

1 OW/40

Eurotex HD

10W/30

Marfak

All purposc

Grease

Texaco

Multigear

Lubricant

EP 85W/90

Texamatic

Fluid 9226

Havoline

Motor Oil low130 or

Eurotex HD l o w n o

Havoline

Owl40

15W/40 or

Motor Oil

W/40

10W/30 or or

Eurotex HD

1OW/30

ß P

. ,

Energrease

Castrol

LM Grease

Duckhams

LU 10 a minimum boiling point of 260°C (500°F)

Esso

Multi- pumosc

Mobil- grease MP

Fina

Marson

HTL 2

Shell

Ketinax A

Marfak

All purpose

Grease

Universal Anti-freeze

See under Anti-freeze section

09.

RECOMMENDED LUBRICANTS , FLUIDSAND CAPACITIES

SERVICE INSTRUCTIONS ALL MARKETS RECOMMENDED LUBRICANTS AND FLUIDS

COMPONENTS

BP l l

Windscreen hinges BP Duckhams

ESSO

Castrol

Energrcase LM Grease LB 10 Ventilator hinges

Ventilator control

Grease Seat slides. Hood retention clips

Door

Esso

MOBIL

Mobil

Multi- purpose

Mobil- grease

Marson

HTL2

Shell

Retinax

; based

All Seasons Screen Washer Fluid Windscreen washers

Graohite Lock Grease Tvoe 'B'

Bonnet ointle

Door locks

(anti-burst)

Inertia reels

~ ~ ~~

DO NOT LUBRICATE. These components are 'life' lubricated at the manufacturing stage

Battery lugs

Earthing surfaces

Where paint has been removed

Air Conditioning

System

Refrigerant

Compressor Oil

METHYLCHLORIDE REFRIGERANTS MUST NOT BE USED

Use only refrigerant 12. This includes 'Freon 12' and Arcton 12'

Shell Clavus 68 BP Energol LPT 68 Sunisco 4GS Texaco Capella E Wax Free 68

C " .

RECOMMENDED LUBRICANTS AND FLUIDS

SERVICE INSTRUCTIONS FOR AMBIENT CONDITIONS OUTSIDE TEMPERATE CLIMATE LIMITS

OR FOR MARKETS WHERE THE PRODUCTS LISTED ARE NOT AVAILABLE

COMPONENTS

Engine

Carburetter dashpotr

Oil can

Oils

Oil bath air cleaners sw120 swi30

5 Wl40

10w130

10w140 low150

15w140 1sw150

20W/40 20Wi50

AiMßIENT TEMPERATURE "C SERVICE CLASSIFICATION WORLDWIDE

Petrol

Diesel oils must meet ß L

Oils must meet BI.

Cars spec. Cars spec.

BLS.22.OL.02 or

API service levcls

SE or SF or SEICC or SFICC or SEICD or S F K D or the CCMC requirements

BLS.22.OL.02 an(

MIL-L-461S2A or

API service levels

CC or CD or

SEICC or SE/CD or SFICC or SFICC or the CCMC requirements

SAE VISCOSITY -30" -20" -10" 0"

10"

20" 30" 40" 50"

~~~

Power steering reservoir

Front and rear

Axle differential

Swivel pin housing

LT230 transfer bo,

Steering box

LI77 eearbox

L'l%iearbox including

:ransfer box

LT85 gearbox

V8 cylinder

ATF M2C 33 F o r G

API GL4 or

MIL-Ir2105

ATF

M2C 33 F or G

Oils must mcet BL

Cars spec.

BLS.22.OL.02 or

API service levels

SE or SF or SE/CC or SEICD or SF/CC or SFICD or the CCMC requirements

Oils must meet ß L

Cars spec.

BLS.22.OL.02 or

API servicc levels

SE or

SF or SEICC

?r SE!C_n or SE!CC

3r SWCD or thc

X M C requirements

90 EI'

80W EP

10W130 IOW140

IOWlS0

IOW140 IOW150

1sw140 15w150

2ow140 20w150

1ow130 10w140

1ow15o

3rake and clutch eservoirs xbrication nipples hubs, ball joints, etc)

Brake fluid must have a minimum boiling point of

260°C (500°F) and comply with FMVSS 116 DOT 3

VLGI-2 multipurpose lithium based grease

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

109

ANTI-FREEZE

Use only UNIVERSAL Anti-freeze or an Ethylene Glycol based anti-freeze, containing no methanol, with non-Phosphate corrosion inhibitors suitable for use in cast iron and aluminium alloy engines to ensure protection of the cooling system against frost and corrosion.

4-cyl. Engines (cast iron)

Engine

Engine (aluminium) i Mixture

One part anti-freeze two parts water

One part anti-freeze one part water

Percentage

Concentration

33%

50%"

50%

Protection

Down to -20°C

Below -20°C to

-36°C

Down to -36°C

IMPORTANT: Coolant solution must not fall below proportions of one part anti-freeze to three parts water, i.e. min.

25" anti-freeze in coolant, otherwise damage to engine is liable to occur.

!..

:..

I .

.!,'

CORROSION INHIBITOR

When anti-freeze is not required the cooling system must be flushed out with clean water and filled with a solution of

ONE PART MARSTONS SQ 36 inhibitor to NINE parts water to provide a 10" mixture concentration.

CAPACITIES

The following capacity figures are approximate and are provided as a guide only. All oil levels must be set using the dipstick o r level plugs as applicable.

Engine sump oil, 4-cylinder..

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

Extra when refilling after fitting new filter, 4-cylinder..

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

Air cleaner oil, 4-cylinder

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

Engine sump oil, V8 cylinder

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

Extra when refilling after fitting new filter, V8 cylinder..

..........

....

:. :

Main gearbox oil, five-speed

LT85 five-speed gearbox

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

Transfer box oil, LT230R five-speed main gearbox..

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

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

LT230T transfer gearbox

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

Main gearbox oil, four-speed

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

Transfer gearbox oil, four-speed main gearbox

Front differential

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

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

Rear differential: Salisbury 8HA

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

Swivel pin housing oil (each)

Fuel tank, rear

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

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

Fuel tank, side (except Station wagon)

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

Fuel tank, side (Station wagon only)

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

Cooling system, 4-cylinder petrol models (standard)

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

. (.

. . . .

Component

Cooling system, 4-cylinder diesel models and heavy duty petrol models

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

Cooling system, V8 cylinder modcls..

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

Steering box manual..

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

Power steering box and reservoir fluid

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

Litres

6,OO

0,85

0,85

5,lO

0,56

2,20

2,80

3,OO

2,80

2,60

3,16

1,70

2,30

0,35

79,50

68,20

45,50

10,30

,oo

12,80

O,43

2,90

Imperial unit

11 .OO pints

1.50 pints

9.00 pints

1.00 pint

3.90 pints

4.90 pints

5.25 pints

4.9 pints

4.70 pints

5.50 pints

3.00 pints

4.00 pints

0.60 pint

17.50 gallons

15.00 gallons

10.00 gallons

18.00 pints

19.00 pints

22.50 pints

0.75 pints

5.0 pints

MAINTENANCE

MAINTENANCE SCHEDULES

Revised Maintenance Schedules are introduced with the commencement of the Land Rover Ninety V8 model range.

The new schedules also apply to four-cylinder, petrol and diesel models, and feature a reduced 10.000 km

(6,000 miles) service. The new schedules supersede previous issues.

Efficient maintenance is one of the biggest factors in ensuring continuing reliability and efficiency. For this reason the following detailed schedules are included so that at the appropriate intervals owners and operators may know what is required. The Maintenance Schedules are based upon intervals of 10.000 km (6,000 miles) or 6 months unless otherwise stated.

Note: The 10.000 km service must be repeated every 10.000 km (6,000 miles) or six months, whichever is first.

The 20.000 km service must be repeated every 20.000 km (12.000 additional maintenance at the intervals specified in the schedule. miles) or 12 months, whichever is first, with

Every

20.000 km

(6.0" miles) (12.000 miles) o r 6 m o n t h s or 12months

0 of all lamps a wipers and washers

0 of handbrake

0 of all doors, bonnet and

12 n

0 pedal pivot of window controls

Lubricate all locks (not steering lock) hinges and door check mechanisms

17 a

0 dust, inspect shoes for wear and drums for condition

Inspect wheel cylinders for fluid leaks

Inspect brake pads for wear, calipers for leaks, and discs for condition

Refit road wheel brake drums n

Refit road wheels to original position

Renew engine oil

Renew engine oil filter

Every 4O.wO

24.000ml km

Renew gearbox oil 30

(6.000 miles)

(12,000 or

Every --

33 a

Every 40.003

24.lXXl km

0 Renew front axle oil 0 oil

Every 4O.lXK) km

24.WOml Renew swivel pin housing oil

38 Every

40.000 km

2 4 , ~ m l

41 a

4O.OlKl ml km

ChecWtop-up swivel pin housing oil

Renew rear axle oil

ChecWtop-up rear axle oil

Lubricate rear suspension upper link ball joint

Lubricate propeller shaft sealed sliding joints

Lubricate propeller shaft universal joints

Lubricate handbrake mechanical linkage

D pipeshnions for chafing, leaks and corrosion

U security

U transmission

47 Check for oil/fluid leaks from stcering and

Every

48,000 m suspension systems

U not blocked, pinched or split 0 of suspension fixings

U joints and gaiters - of propeller shaft coupling bolts

U l Clean electric fuel pump filter

I for wading (refit) 0

(Diesel)

Check c ~ n d l t i e n heater wiring fs: fraying, chafing and deterioration

(diesel only)

Every40.000

24.000ml km

Remove diesel injectors, clean, test and refit

MAINTENANCE

1O.ooO

61 km miles) or 6 months or

Every km miles) months -

Checkladjust valve clearance (all models

Every

IO.o(K) km

(6.000 or

6 miles)

Every

2O.ooO km b r 12 months

41.000

24.lXM ml

Renew distributor points (not V8)

V8)

0 except V8)

Cleardadjust spark plugs 0

EveryJ0.000 ml

0 or renew km

0 (V8)

Clean engine breather filter (all models

Lubricate distributor (not V8)

0 Check voltage drop between coil

CB and earth

Check dwell angle - adjust as necessary

(not V8) 0

ChecWadjust ignition timing

Note: It is important that the ignition timing, dwell angle and carburetter adjustments are set in accordance with the vehicle engine spenfcation

68 Every60.000 km

69 36.000ml

Renew brake Servo filter

Check brake Servo hose for security and n

0 Check operation of pulsair check valves

Check crankcase breathing system for leaks, hoses for security and condition

Checktop-up fluid in power steering reservoir

100

0 and fuel Octane rating. Refer to the relevant repair a carburetter mixture settings with engine at

0 normal running temperature

Check operation of air intake temperature control system (V8)

Carry out road or roller test Check: 0

For excessive engine noise

Clutch for slippindjudder/spinning

Gear selectiodnoise

Steering for noise/abnormal effort required

All instruments, pressure, fuel and

Check/top-up clutch fluid reservoir

Checktop-up brake fluid reservoir

Check/top-up windscreen and rear washer

0 hoscs for security and condition

Check power steering system for leaks, hydraulic pipes and unions for chafing and

0 corrosion

- diesel)

HT leads for

0 tracking

101

102

103

104

105

106

107

108

109

110

111

112

113

114

0 temperature gauges, warning indicators

Heatedrearscreen

Shock absorbers (irregularities in ride)

Foot brake, on emergency stop, pulling to one side, binding, pedal effort

Operation of inertia seat belts

Roadwheel balance

Transmission for vibrations

For body noises (squeaks and rattles)

Fuel governor cut-off point

Engineidlespecd a

WARNING: Two-wheel roller tests must be restricted to 5 k d h (3 m.p.h.) because the Land Rover One Ten and c3

Ninety is is constant four-wheel drive.

At 100.000 km (60?000 mile) intervals it is imperative that the camshaft drive belt be renewed, failure to do so could result in serious engine damage.

RECOMMENDATIONS

At 30.000 k m (18,000 mile) intervals or every 18 months, whichevcr is the sooner, the hydraulic brake fluid should be completely renewed.

At 40.000 km (24,000 mile) intervals remove the Pulsair injection manifold and connecting pipes, ensure that the internal bores and the cylinder head drillings are clean and free from obstructions, clean as necessary and refit.

(Emission control V8 petrol engines)

At 60.000 km (36,000 mile) intervals or every 3 years, whichever is the sooncr, all hydraulic brake fluid, seals and flexible hoses should be renewed. all working surfaces of the master cylinder, wheel cylinders and caliper cy!inders should be examined and renewed where necessary.

At 60.000 km (36,000 mile) intervals remove all suspension dampers, test for correct operation, refit or renew as necessary.

Vehicles fitted with free wheeling front hubs

The hubs require no routine maintenance. When the hub bearings are adjusted, or any time the vehicle has been used for wading, the moving parts of the free wheel hubs should be lightly smeared with Rocol 1000 grease or a similar molybdenum disulphide bearing grease.

&"-?

-..

T a;,-;;.

. . .. ...

LUBRICATION

This first part of the maintenance section covers renewal of lubricating oils for the major units of the vehicle and other components that require lubrication, as detailed in the ‘Maintenance schedules’. Refer to the

‘General specification data’ for capacities and recommended lubricants.

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

Draining of used oil should take place after a run when the oil is warm. Always clean the drain and filler-level plugs before removing. In the interests of safety disconnect the vehicle battery to prevent the engine being started and the vehicle moved inadvertently, while oil changing is taking place.

Allow as much time as possible for the oil to drain completely except where blown sand or dirt can enter the drain holes. In these conditions clean and refit the drain plugs immediately the main bulk of oil has drained.

Where possible, always refill with oil of the make and specification recommended in the lubrication charts and from sealed containers.

Illustration A. V8 engine.

MAINTENANCE

Renew oil filter

5 . Place an oil tray under the engine.

6. Unscrew the filter anti-clockwise, using a strap spanner as necessary.

7. Smear a little clean engine oil o n the rubber washer of the new filter, then screw the filter on clockwise until the rubber sealing ring touches the machined face, then tighten a further half turn by hand only.

Do not overtighten.

RENEW ENGINE OIL AND FILTER

DRAIN THE OIL

1. Drive vehicle to level ground.

2. Run the engine to warm the oil; switch off the ignition and disconnect the battery for safety.

3. Place an oil tray under the drain plug.

4. Remove the drain plug in the bottom of the sump at the left-hand side -

4-cylinder engines. Allow oil to drain away completely and replace the plug and tighten to the correct torque.

NOTE: The example shown below is a

4 cylinder engine sump.

ST1022M

Illustration B. 2.5 Diesel engine.

ST 918M

1 1

MAINTENANCE

Renew oil filter

8. Place oil tray under engine.

9. Unscrew filter retaining bolt.

10. Remove the container.

11. Remove the element.

12. Discard the used filter element and large rubber washer.

13. Wash the container in kerosene.

14. Place the new filter element in the container and reassemble the unit, using the new large rubber washer supplied with the element.

15. Ensure that all the sealing washers are in position and intact, and that the container is correctly located in the adaptor.

16. Tighten the filter retaining bolt to the correct torque. Do not overtighten.

RENEW MAIN AND TRANSFER GEARBOX OILS

DRAIN AND REFILL LT77mm MAIN GEARBOX

4-cylinder engines

1. Drive the vehicle to level ground and place a suitable container under the gearbox to catch the old oil.

2. Remove the gearbox and extension case drain plugs and allow the oil to drain completely. Wash the extension case filter in kerosene and refit the plugs using new washers, if necessary, and tighten to the correct torque.

Refill sump with oil -all models

17. Check that the drain plug is tight.

18. Clean the outside of the oil filler cap, remove it from the rocker cover and clean the inside.

19. Pour in the correct quantity of new oil of the correct grade from a sealed container to the high mark on the dipstick and firmly replace the filler cap.

20. Run the engine and check for leaks from the filter.

Stop the engine, allow the oil to run back into the sump for a few minutes, then check the oil level again and top up if necessary.

3 . Remove the oil filler-level plug and inject the approximate quantity of new oil of the correct make and grade until it begins to run out of the filler-level hole. Fit the plug and tighten to the coirect torque. Since the plug has a tapered thread it must not be overtightened. Wipe away any surplus oil.

DRAIN AND RENEW 230R AND 230T TRANSFER

GEARBOX (4-cylinder engine)

1. Drive the vehicle to level ground and place a container under the gearbox to catch the old oil.

2. Remove the drain plug and allow the oil to drain.

Fit the plug using a new washer, if necessary, and tighten to the correct torque.

3. Remove the filler-level plug and inject the approximate quantity of the recommended oil until it begins to run from the plug hole. Fit the level plug and tighten only to the correct torque, do not overtighten, wipe away any surplus oil.

MAINTENANCE

110

DRAIN AND RENEW LT95 TRANSFER GEARBOX

OIL

1. Drive vehicle to level ground and place a container beneath the gearbox to catch the old oil.

2. Remove the drain plug and allow time for the oil to drain completely.

3. Clean and refit the drain plug using a new washer, if necessary and tighten to the correct torque.

4. Remove the oil filler-level plug and inject the approximate quantity of a recommended oil until it begins to run from the hole. Clean and fit the plug and tighten to the correct torque. overtighten. Wipe away any surplus oil.

Do not

ST1070M

DRAIN AND RENEW LT95 MAIN GEARBOX (V8 engines)

1. Drive the vehicle to level ground and place a container under the gearbox to catch the old oil.

2. Remove the drain plug, washer and filter from the bottom of the gearbox casing and allow the oil to drain completely.

3. Wash the filter in petrol, allow to dry and fit to the casing. Using a new washer, if necessary, fit the plug and tighten to the correct torque.

4. Remove the oil filler-level plug from the side of the gearbox and inject the approximate quantity of the correct oil until it begins to run from the filler-level hole. Clean and refit the plug using a new washer and tighten to the correct torque. Wipe away any surplus oil.

RENEW FRONT AND REAR AXLE OIL

1. Drive the vehicle to level ground and place a container under the axle to be drained.

2. Using a spanner with a 13 mm (0.5 in) square drive remove the drain plug and allow the oil to drain completely. Clean and refit the drain plug.

3 . Remove the oil filler-level plug and inject new oil of a recommended make and grade until it begins to run from the hole. Clean and fit the filler-level plug and wipe away any surplus oil.

NOTE: Whilst the illustration shows a ‘90’ model front differential, the procedure is the same for all axles.

MAINTENANCE

RENEW SWIVEL PIN HOUSING OIL

1. Drive the vehicle to level ground and place a container under each swivel housing to catch the used oil.

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

3. Remove the oil filler-level plug and inject the recommended make and grade of oil until oil begins to run from the level hole. Clean and fit the level plugs and wipe away any surplus oil.

TOP-UP MANUAL STEERING

BOX

1. Remove the oil filler plug and observe the oil level which should be 25 mm (1.0 in) below the top of the filler hole.

2. If necessary top-up to the correct level with a recommended oil. Clean and refit the plug and wipe away any surplus oil.

LUBRICATE PROPELLER SHAFTS

1. Clean all the grease nipples on the front and rear propshaft universal joints, and sliding portion of the rear shaft.

2 . Charge a low pressure hand grease gun with grease of a recommended make and grade and apply to the grease nipples.

3. Remove the screwed plug from the front shaft and fit a suitable grease nipple.

4. Disconnect one end of the front propeller shaft and compress the sliding portion whilst applying grease. It is necessary to compress the shaft to prevent over filling with grease. It should be noted that this sliding portion must only be lubricated at

40.000 km (24,000 mile) intervals.

5. Reconncct the propeller shaft, remove the grease nipple and fit the screwed plug.

ST 925M

RENEW AIR CLEANER OIL

(early models)

- litre engines

1. Slacken wing nut and release the clamping strap securing the complete air cleaner.

2 . Disconnect the outlet elbow from the intake pipe and remove the clcaner from thc vehicle.

3. Remove the oil bowl from the bottom of the cleaner by releasing the three securing clips.

4. Clean all dirty oil and sludge from the bowl and refill with fresh engine oil to the level indicated by a ring formed in the pressing; the capacity is approximately 0,85 litre (1.5 imperial pints).

5. Clean the spiral in the cleaner body by swilling the complete body in paraffin and shake off the surplus.

6. Remove and clean the air intake cap.

7. Clean the wire mesh filter.

8. Reassemble filter using a new scaling ring.

9. Refit the complete unit into the vehicle. ct

-d

'. ..

..-I

1.1,

TOP-UP BRAKE VACUUM PUMP

..':?

Diesel engine

OIL

1. Slacken the drive belt, and the pump pivot bolts and nuts and slip the belt from the pulley.

2. Move the pump to an upright position and temporarily tighten the nuts and bolts to maintain this position.

3. Turn the pump pulley so that the indicating marks on the pulley hub and pump body line up.

MAINTENANCE

TOP-UP CARBURETTER PISTON DAMPER only

1. Unscrew the cap on top of both suction chambers and withdraw the damper.

2. Top-up the reservoir with engine oil to within

12 mm (0.5 in) from the top of the hollow piston rod. Refit t h e damper and secure the cap.

'..

. .

:, :'

4. Remove the oil level plug at the rear of the pump and if necessary inject a recommended SAE

15W-50 oil up to the level of the hole.

5 . Refit the level plug, and fit and tension the drive belt.

RENEW LT85 MAIN GEARBOX OIL

Drain and refill monthly when operating under severe wading conditions.

T o change the gcarbox oil proceed as follows:

1. Immediately after a run when the oil is warm, drain off the oil into a container by removing the drain plug and washer from the bottom of the gearbox casing.

2. Remove the oil filter.

/ 4 4

ST 1008M

REAR SUSPENSION BALL JOINT

1. Apply a grease gun to the nipple using a recommended grease.

3. Wash the filter in clean fuel; allow to dry and replace.

4. Clean and refit drain plug and washer and refill gearbox through the oil level/filler plug, with the correct grade of oil, to the bottom of the oil

1eveYfiller hole. For capacity see Data Section.

MAINTENANCE

13. Fit the road wheels, lower the vehicle and finally tighten the wheel retaining nuts.

GENERAL MAINTENANCE AND ADJUSTMENT

This second part of the maintenance section covers adjustments and items of general maintenance as dictated by the ‘Maintenance Schedules’. However, only maintenance operations that are not included i n the Overhaul Sections of the manual appear in this section.

EXAMINE AND RENEW FRONT BRAKE FRICTION

PADS

Examine the friction pads for wear and if less than

3 mm (0.125 in) thick or oil contaminated, they must be renewed on both wheels at the same time, as follows:

NOTE: See Book 4 Section 70 for latest method of friction pad retension. l.+Slackcn both front wheel nuts and jack-up the vehicle and lower onto axle stands, and remove whecls.

2. Clean the exterior of the calipers.

3. Remove the split pins from the brake caliper.

4. Remove the retaining springs.

5 . Withdraw the friction pads.

6. Clean the exposed parts of the pistons, using only new brake fluid.

CLEAN AND CHECK AXLE BREATHERS valve type (where fitted)

1. Clcan the outside of the breather and unscrew from the axle tube.

2. Wash the breather in petrol and shake to ensure that the ball valve is free. tube.

3. Lubricate the ball with engine oil and refit to axle I

7. Using piston clamp 186672 press each piston back into its bore, whilst ensuring that the displaced brake fluid does not overflow from the reservoir.

8. Smear the faces of the pistons with Lockheed disc brake lubricant taking care not to !et any reach the lining material.

9. Insert the new friction pads.

10. Place the friction pad retaining springs in position and fit new split pins and splay the ends.

11. Apply the footbrake several times to locate the pads.

12. Check the fluid reservoir and top-up if necessary.

Remote axle breathers - where fitted

Pipes attached to the breathers on the axles terminate

I , at p i f i t s iiiside the chassis members oil eariy muueis and into the engine compartment on later vehicles. This allows the axles to breath whilst the vehicle is traversing mud and water. N o maintenance is required except to ensure that the pipe: do not become blocked, kinked, or split, or damaged in any other way to prevent proper breathing.

CHECK STEERING BALL JOINTS

Ball joints are lubricated for the normal life of ball joints during manufacture and require no further lubrication. This applies only if the rubber gaiter has not become dislodged or damaged. The joints should be checked at the specified mileage intervals but more frequently if the vehicle is used under arduous conditions.

1. Check for wear in the joints by moving the ball joint up and down vigorously. If free movement is apparent renew the complete joint assembly.

ADJUST REAR BRAKES

Land Rover One Ten Vehicles

1. Raise up vehicle and lower onto axle stands.

2. Each shoe is independently set by means of a hexagon adjuster. Check that the wheel turns freely and turn one adjuster until the shoe is locked against the drum. Slacken off sufficiently for the wheel to turn freely

- approximately two serrations on the snail cam.

3. Repeat the above procedure for the second brake shoe and the opposite wheel.

4. Remove the axle stands and road test the vehicle brakes.

CHECK FRONT WHEEL ALIGNMENT

Use recognised wheel alignment equipment to perform this check and adjustment. See 'General Specification and Data' section for the correct alignment. Check and adjust with the vehicle on level ground.

1. Set the road wheels to the straight ahead position and push the vehicle forward a short distance.

2. Slacken the clamp bolts securing the ball joints at both ends of the track rod.

3. Twist the track-rod to decrease or increase its effective length as required to achieve the correct alignment.

4. Push the vehicle rearwards whilst moving the steering wheel from side to side to settle the ball joints. Then with the wheels in the straight ahead position push the vehicle forward a short distance and recheck the alignmcnt. If necessary make further adjustments. When the alignment is correct tighten the ball joint clamp bolts.

The ball joint pins must be central in their housing and not inclined to one side. See section 57. s-r

Land Rover Ninety Vehicles

The shoes are set by a single hexagon adjustment bolt operating through a serrated snail cam enabling both shoes to be adjusted to obtain the best results.

1. Raise-up the vehicle on to axle stands.

2. Check that the wheel rotates freely then turn the adjuster until the brake shoes are in firm contact with the drum.

3 . Slacken o f f the adjuster just sufficiently for the drum to rotate freely.

4. Repeat the procedure for the other wheel.

5. Remove the axle stands and road test the vehicle.

MAINTENANCE

AD JUST TRANSMISSION BRAKE (Handbrake)

Set the vehicle on level ground and chock the wheels.

Release the handbrake fully.

Remove the clevis pin connecting the handbrake lever to the relay at the gearbox end.

\\ \\ \M\

6. Fit the clevis pin, washer and a NEW split pin.

7. Slacken the adjuster 1 o r 2 notches until handbrake shoes just clear the drum.

8. Apply the handbrake gradually. The drum should still rotate on the first ratchet and start to come on at the second ratchet.

CAUTION: DO NOT over adjust the handbrake, the drum must be free to rotate when the handbrake is released, otherwise serious damage will result.

DRAIN FLYWHEEL HOUSING

1. The flywheel housing can be completely scaled to exclude mud and water under severe wading conditions, by means of a plug fitted in the bottom of the housing.

2. The plug should only be fitted when the vehicle is expected to do wading or very muddy work.

3. When the plug is in use it must be removed periodically and all oil allowed to drain off before the plug is replaccd

i

L -

4. Turn the adjuster on the back plate clockwise until the shoes are fully expanded against the drum,

Illustration A . 4-cylinder vehicles.

5 . Adjust the outer sheath of the handbrake cable by means of the two locknuts at the gearbox end until the holes in the clevis on the inner cable line up with the hole in the relay lever.

Illustration B. V8 vehicles.

ST 1012M

ST1074M

4. When plug is not in use it should be stowed as follows:

4 cylinder models

- kit screwed into housing near drain hole.

I *.:

MAINTENANCE

1101

DRAIN ENGINE TIMING COVER

1. The timing cover can be completely sealed to exclude mud and water under severe wading conditions, by fitting a plug in the drain hole at the bottom of the cover.

2. The plug should only be fitted when the vehicle is expected to d o wading or very muddy work.

3. When the plug is in use it must be removed periodically and any oil present allowed to drain off before the plug is replaced.

NOTE: There should not be any oil in the timing cover, but if there is, the cause should be investigated as soon as possible, as the timing belt will deteriorate if it becomes contaminated with oil.

4. When the plug is not in use it should be stowed in the tapped hole adjacent to the drain hole.

ST209

RENEW AIR CLEANER ELEMENT

2.25 Petrol engines

1. Disconnect the air cleaner hose.

2. Pull up the three clips and lift out the air cleaner canister.

3 . Unscrew element wing nut and sealing washer.

4. Remove and discard the element. DO NOT attempt to clean the element, fit a new one during reassembly.

5 . Clean interior of canister.

6. Fit a new element and sealing washer.

I.:.

_. .

CLEAN ENGINE TIMING COVER FILTER

Diesel only

A gauze filter is fitted at the bottom of the engine timing cover to help prevent mud and other debris entering the drain hole, when the wading plug is not in use. The filter must be removed and cleaned periodically, to ensure that it does not become blocked and prevent the timing cover draining properly. Under normal circumstances, the filter should be cleaned at the intervals specified in the Maintenance Schedule or, more frequently if the vehicle operates regularly in wet or dusty conditions.

1. From underneath the vehicle, remove the four bolts and plain washers and, withdraw the wading plug plate from the bottom of the timing cover.

2. Wash the filter in kerosene or clean fuel. Brush off any mud or other debris aiid ensure that the whole filter is quite clean.

3. Check the condition of the gasket for the wading plug plate. If necessary, fit a new gasket.

4. Refit the wading plug plate. Tighten the securing bolts.

ST206 continued

MAINTENANCE

Check air cleaner dump valve

The dump valve provides an automatic drain for the air cleaner and is fitted in the base of the air cleaner support bracket.

7. Squeeze open the dump valve and check that the

8. interior is clean.

Also

check that the rubber is flexible and in a good condition.

If necessary, remove the dump valve to clean the interior. Fit a new valve if the original is in a poor condition.

Check air cleaner dump valve

7. Squeeze open the dump valve and check that the interior is clean. Also check that the rubber is flexible and in a good condition.

8. If necessary, remove the dump valve to clean the interior. Fit a new valve if the original is in a poor

- t . ;, condition.

Fit air cleaner

Fit a new element and reassemble the air cleaner.

10. Fit the air cleaner canister.

11. Fit the breather hose.

12. Fit the air cleaner hose.

13. Secure with the retaining straps and nuts.

Fit air cleaner

9. Fir air cleaner canister and secure with the clips.

10. Connect the air cleaner hose.

RENEW

AIR

CLEANER ELEMENT

1. Unscrew the two air cleaner strap retaining nuts.

2. Disconnect the air cleaner hose.

3. Remove the engine breather hose.

Withdraw air cleaner canister.

5. Unscrew element wing nut and washer and remove filter seal.

6. Remove and discard the element. DO NOT attempt to clean the element, fit a new one during reassembly and secure with the wing nut.

Petrol engine

SEDIMENT BOWL

1. Remove the bowl by slackening the thumb screw and swinging the retainer to one side.

2. Remove and clean the filter gauze in clean petrol.

3 . Ensure that the sealing washer is in good condition. .s/

Replace gauze and refit the bowl.

5. Prime the pump by operating the hand lever. r;

ST1068M

?!!

CLEAN ELECTRIC F’UEL PUMP FILTER later 2.25 Petrol engine vehicles

The pump is located mid-way along the right hand side of the chassis.

1. Release the three bolts and remove the protective cover -

RENEW FUEL FILTER ELEMENT

4-cylinder and V8

The element provides a filter between the pump and carburetter and is located adjacent to fuel pump on the right hand side of the chassis.

1. Release the three bolts and remove the protective cover. See ‘Clean electric fuel pump filter’.

2. Unscrew the centre bolt.

3 . Withdraw the filter bowl.

4. Remove the small sealing ring and remove the element.

5. Withdraw the large sealing ring from the underside of the filter body.

6. Discard the old element and replace with a new unit.

7. Ensure that the centre and top sealing rings are in good condition and replace as necessary.

8. Fit new element, small hole downwards.

9. Refit sealing rings (small and large).

10. Replace filter bowl and tighten the centre bolt.

ST 1014M 1 r .

2. From beneath the vehicle disconnect the fuel inlet pipe from the pump and blank the end of the pipe by suitable means t o prevent fuel draining from the tank.

3. Release the end cover from the bayonet fixing.

4. Withdraw the filter and clean by using a compressed air jet from the inside of the filter.

5 . Remove the magnet (where fitted) from the end cover and clean. Replace the magnet in the centre of the end cover.

6 . Reassemble the fuel pump and refit the fuel inlet pipe.

7. Use a new gasket for the end cover if necessary.

Fit the protective cover.

ST1075M k G 2

10 MAINTENANCE

RENEW FUEL FILTER ELEMENT

Drain off Water

1. Slacken off drain plug to allow water to run out.

2. When pure diesel fuel is emitted, tighten drain

Plug-

FUEL SEDIMENTER

The sedimenter increases the working life of the fuel filter by removing the larger droplets of water and larger particles of foreign matter from the fuel.

Drain off water as follows:

Drain off Water

1. Slacken off drain plug to allow water to run out.

2. When pure diesel fuel is emitted, tighten drain plug. Dismantle and clean as detailed below.

ST062

Renew filter

3. Support element holder.

4. Unscrew thc special bolt on top of the filter, the element holder can now be removed.

5. Remove and discard the used element.

6 . Wash the element holder in petrol or fuel oil.

7. If necessary renew both the large rubber washer and the small rubber washer in the filter top, also renew the large rubber washer in the element holder.

8. Push the new elcment onto the filter top spigot with the holes in the element to the top.

9. Fit the element holder to the bottom of the element, and secure with the special bolt.

10. Prime the system and check for fuel leaks.

ST 101 7M

- /

Clean element

3. Disconnect fuel inlet pipe at sedimenter and raise pipe above level of fuel tank to prevent draining from tank. Support in this positon.

4. Support sedimenter bowl and unscrew bolt on top of unit and remove bowl.

5. Remove the sedimenter element.

6.

Clean all parts in kerosene.

7. Fit new seals and reverse removal procedure.

8. Slacken off the drain plug, when pure diesel fuel runs out tighten plug.

9. If necessary, prime the system.

10. Start engine and chcck for leaks from sedimenter.

C u ”

ST 1018M

I c.

,>,4 *

RENEW DUCELLIER DISTRIBUTOR

4-cylinder engines

POINTS

Renew Points

1. Release the spring clips and remove the distributor cap.

2. Pull off the rotor arm.

3. Remove the dust shield.

4. Remove the retaining screw and remove the fixed contact point.

5 . Slide the spring clip rearwards.

6. Disconnect the suppressor lead from the connector block.

7. Disconnect the lead from ignition coil.

8. Remove insulation washer from the moving contact point.

9. Lift off the moving contact point complete with leads and connector block from the distributor body.

10: Fit the new moving point over post.

11. Locate the leaf spring in the plastic guide.

12. Fit the insulation washer.

13. Secure the assembly with the spring clip.

14. Fit the connector block to the distributor body.

15. Connect ignition coil lead.

16. Fit suppressor lead to connector block.

17. Fit the fixed contact point and loosely retain with the screw.

MAINTENANCE

Adjust points

NOTE: The following two instructions describe the adjustment of the contact points. The accompanying illustration shows it being done with the aid of special tool 18G1308. Whilst the points can be adjusted to the datum setting only (see data) without the tool full distributor adjustment, i.e. dwell angle, dwell variation and vacuum advance can only be achieved by using this tool in conjunction with engine diagnostic equipment. It is essential that the above adjustments are carried out in order to maintain correct emission levels and maximum engine efficiency.

18. Rotate the engine until a cam of the rotor fully opens the points.

19. Using a feeler, adjust the position of the fixed contact point to the datum setting and tighten the retaining screw.

20. Check and adjust the dwell angle, dwell variation and vacuum advance.

MAINTENANCE

ADJUST DUCELLIER DISTRIBUTOR

Petrol engine

Service tool:

1861308

Check and Adjust Dwell Angle

NOTE: The following six instructions can only be carried out using engine diagnostic equipment and special tool 18G1308.

1. Start the engine, disconnect the vacuum pipe from the vacuum unit and with the engine idling check the dwell angle - required stop the engine, remove the distributor cap, rotor arm and dust cover, slacken the fixed contact retaining screw and using the eccentric-post end of the special tool, as illustrated, make an appropriate adjustment. Tighten the retaining screw, reassemble the distributor and recheck the dwell angle.

Check vacuum advance

NOTE:

If the vacuum unit has been removed or the distributor dismantled, the vacuum advance must be checked and if necessary adjusted.

4. Disconnect the vacuum pipe and connect a vacuum pump to the unit.

5. Start and run the engine at idle speed and using a timing light, slowly increase the vacuum and note the point at which vacuum advance starts and compare the figure with that given in data.

6.

Adjustment of the serrated cam, with the special tool, one tooth at a time, will alter the point at which vacuum advance starts.

Check and adjust dwell variation

- - wear within the distributor. This may be checked as follows:

2. Disconnect the vacuum advance, start the engine and increase the speed to 2000 r.p.m. A variation outside the tolerance given in data indicates that the distributor has a mechanical fault which cannot be rectified by adjustment.

!f the k’aiiatioi; is acceptabk, reconnect the vacuum pipe, start the engine and increase the engine speed to 2,000 r.p.m. and release the throttle. Check the dwell variation and if necessary adjust by tuming the eccentric ‘D’ post with the special tool (female ‘D’ end). Setting the dwell for minimvin variation may alter the basic setting and this must be rechecked at idle speed.

RENEW LUCAS CONTACT BREAKER SLIDING

CONTACTS

The contact set should be renewed every 40.000 km

(25,000 miles).

Remove the old contacts

1. Remove the distributor cap.

2. Remove the rotor arm.

3. Remove the retaining screw and lift the contact set complete from the plate.

4. Press the contact set spring and release the terminal plate and leads from the spring.

Fit new contacts

5 . Clean the points with petrol to remove the protective coating.

6.

Press the contact spring and fit the terminal plate with the black lead uppermost.

7. Fit the contact set to the moving plate, ensuring that the peg, underneath the contact pivot, locates

8. in the hole in the moving plate.

The sliding contact actuating fork must also locate

9. over the fixed peg.

Loosely secure the assembly with the scrcw, plain and spring washer.

10. Check that the contact leaf spring locates properly in the insulation shoe.

MAINTENANCE

1101

Adjust gap

11. Rotate the crankshaft until the contact heel is on the highest point of a cam.

12. Adjust the gap by inserting a screwdriver blade between the ‘V’ shaped notch and pip and twist the

13. screwdriver.

Insert a 0,35 to 0,40 m m

(0.014 to 0.016 in) feeler gauge between the points and adjust to a sliding fit and tighten the retaining screw.

14. Fit the rotor arm.

ST1082M

RENEW DISTRIBUTOR CONTACT SET

- engine

Fixed contact type

1. Unclip and remove the distributor cap.

2. Withdraw the rotor arm.

3. Remove the contact breaker spring anchor nut and lift off:

(a) the top-half of insulation bush

(b) the low tension lead (black)

Remove the contact breaker retaining screw, plain and spring washer and remove contact set assembly.

5 .

6.

Remove the complete insulation bush.

Fit the contact breaker set ensuring that the small post protruding from below the contact set locates through the hole in the cover plate into the hole in the end of the vacuum unit actuating lever, secure with the screw, plain and spring washers. continued

MAINTENANCE

7. Assemble the contact breaker spring insulating bushes and electrical leads, as illustrated, in the following sequence:

(a) lower bush

(b) spring

(d) capacitor lead

(e) top bush and secure with the anchor spring nut.

8. Apply a few drops of engine oil to the distributor cam lubrication pad.

3,lO-

RR090

Adjust points -both types

9. Turn the engine in the direction of rotation until the contacts are fully open or the heel of the contact set is on the highest point of the cam.

10. Using a feeler gauge and the dwell angle adjuster on the side of the distributor, set the points to a nominal gap of 0,35 to 0,40 mm (0.014 to 0.016 in).

11. At the earliest opportunity check and adjust the dwell angle

- equipment.

12. Fit the rotor arm and distributor cap ensuring that the H.T. pick-up brush moves freely.

Sliding contact type

1. Release the clips and remove the distributor cap.

2. Remove the rotor arm from the cam spindle.

3. Remove the retaining screw and washers and lift the complete contact breaker assembly from the moveable plate.

4. Remove t h e nut and plastic bushes from the terminal post to release the leads and spring.

5. Discard the old contact breaker assembly.

6. Clean the new points with petrol to remove the protective coating.

7. Connect the leads to the terminal post in the following sequence:

(a) lower plastic bush

(b)

red lead tab

(d) black lead tab

(e) upper plastic bush

(f) retaining nut.

8. Fit the contact set to the moving plate ensuring that the two pegs locate in the holes.

ST1083M

-..

;::;.,

CLEAN AND LUBRICATE V8 ENGINE

'y?

DISTRIBUTOR

Fixed contact type

1. Remove distributor cap.

2. Remove rotor arm.

3. Lightly smear the cam with clean engine oil.

Add a few drops of thin machine oil to lubricate the cam bearing and distributor shaft.

5. Wipe the inside and outside of the distributor cap with a soft dry cloth.

6.

Ensure that the carbon brush works freely in its holder.

7. Refit rotor arm and distributor cap

MAINTENANCE

CLEAN AND LUBRICATE DUCELLIER

DISTRIBUTOR

1. Remove the distributor cover and lift off the rotor arm and anti-dust shield.

2. Inspect the contact breaker points; if burnt or worn they should be renewed.

3.

Very lightly smear the cam with grease

Retinax.

4. Lubricate the pressure pad with grease

Retinax.

Add a few drops of oil to the felt pad in the top of the cam spindle.

6. Turn the engine until the distributor centrifugal weight pivot post is visible through the cut-out in the base plate and lubricate the pivot post with a drop of oil. Repeat for the opposite pivot post.

7. Carefully wipe away all surplus lubricant; and ensure that the contact breaker points are clean and dry.

8. Fit the anti-dust shield.

9. Refit the rotor arm, engage the slot in the spindle and push down firmly.

10. Wipe clean with dry nap-free cloth, the inside and outside of the distributor cover, particularly between the electrodes, and fit the distributor cover.

Sliding contact type

1. Remove distributor cap.

2. Remove rotor arm.

3. Lightly smear the cam with clean engine oil.

4. Add a few drops of thin machine oil to lubricate the cam bearing and distributor shaft.

5 . Wipe the inside and outside of the distributor cap with a soft dry cloth.

6 . Ensure that the carbon brush works freely in its holder.

7. Lubricate the actuator ramps and contact breaker heel ribs with Shell Retinax or equivalent grease.

8. Grease the underside of the heel actuator.

9. Apply grease to the fixed pin and actuator fork.

10. Refit rotor arm and distributor cap.

CLEAN V8 ENGINE ELECTRONIC IGNITION

DISTRIBUTOR

80.000 km

(48,000 miles)

Remove the distributor cap and rotor arm and wipe inside with a nap-free cloth.

DO NOT DISTURB the clear plastic insulating cover which protects the magnetic pick-up module.

R R 0 9 2

MAINTENANCE

CLEAN AND LUBRICATE LUCAS DISTRIBUTOR

1. Clean and lightly grease the cam with Shell Retinax o r equivalent and remove any surplus lubricant.

2. Using the same grease lubricate the underside of the heel actuator.

3. Grease the actuator ramps and contact breaker heel ribs.

4. Apply grease to the fixed pin and the actuator fork.

5. Apply a drop of clean engine oil to the felt pad underneath the rotor arm.

6. Every 40.000 km (25,000 miles) lubricate the automatic advance mechanism by injecting one or two drops of engine oil through the aperture in the base plate.

7. Wipe the internal and external surfaces of the distributor cap with clean dry nap-free cloth and fit the cap to the distributor body.

ST1084M

CHECK AND ADJUST VS ENGINE DISTRIBUTOR

TIMING

Using Electronic Timing Equipment

A pointer on the timing cover and marks on the crankshaft pulley indicate positions around T.D.C. on

No. 1 cylinder (i.e. front cylinder on left-hand bank).

Refer to 'Engine Tuning data' for appropriate ignition timing.

Engine speed accuracy during ignition timing is important. Any variation from the required idle speed, particularly in an upward direction, will lead to wrongly set ignition timing.

1. Connect a stroboscopic timing light as instructed by the manufacturer. The engine is timed on No. 1 cylinder.

2 . Run the engine at idle speed.

3. Position the timing light to illuminate the crankshaft pulley and scale.

- t

WARNING: Ensure that personnel and equipment are kept clear of the rotating cooling fan while using the timing light.

4. If the timing is correct the pulley mark indicated in the Tuning Data will show. If correct, instruction 5 may be ignored.

5. With the engine still running at idle speed, slacken the clamp bolt and carefully rotate the distributor body as required until the correct pulley mark shows. Turn anticlockwise to advance and clockwise to retard.

6. Tighten the clamp bolt with the unit in this position.

"!, '. .."

I ,

*-‘r!t

-2,

.i;C’

. I

CLEAN, ADJUST

OR

RENEW SPARK PLUGS

1. Withdraw the H.T. leads from the spark plugs by gripping the shrouds, do not pull on the leads.

2. Using an appropriate plug spanner, remove the spark plugs.

ST1087M

MAINTENANCE

Refit or renew spark plugs

11. Check that the washers are fitted to the plugs.

12. It is important that only spark plugs specified in

Data section are used for replacements.

13. Incorrect grades of plug may lead to piston overheating and engine failure.

14. Wash new plugs in petrol to remove the protective coating, then set the electrode gaps to the appropriate figures given in ‘Engine Tuning data’.

15. Fit the plugs and washers to the engine but do not overtighten.

16. Examine high tension leads, including the coil to distributor lead, for insulation cracking or corrosion at end contacts. Fit new leads as necessary.

17. In addition to correct firing order, high tension leads must be fitted in correct relation to each other to avoid cross firing, as illustrated. This is particularly important on the V8 engine.

First illustration. 4-cylinder engine.

Second illustration. V8 engine.

18. When pushing leads on plugs ensure ferrules within shrouds are firmly seated on plugs.

. .

Clean and set gaps

3. Fit plug in plug cleaning machine.

4. Wobble plug with circular motion while operating abrasive blast for a maximum of four seconds.

CAUTION: Excessive abrasive blasting will erode insulator nose.

5. Change to air blast only and continue to wobble plug for a minimum of thirty seconds to remove abrasive grit from plug cavity.

6. Wire-brush plug threads, open gap slightly.

7. Using point file, square off electrode surfaces.

8. Set electrode gap, see ‘Engine Tuning data’,

9. Test plugs in accordance with cleaning machine manufacturer’s instructions. If satisfactory, refit plugs in engine.

10. If no machine is available carefully wire brush electrodes and blow or wash away carbon particles.

ST052

Illustration shows:

Dirty o r unsatisfactory electrode

B. Filing plug electrodes

C. A

clean

plug correctly set

ST051

A B C

1x1

MAINTENANCE

CLEAN AND TEST HEATER PLUGS engines

Diesel

REMOVE THE PLUGS

1. Disconnect the battery.

2. Remove the terminal nut from each heater plug.

3 . Detach the heater plug lead and washer from each

Plug.

Remove the heater plugs.

Clean and inspect

5. Remove carbon from base of heater plugs to avoid the possibility of short circuiting of the element.

Do not sandblast.

6. Examine the element for signs of fracture and deterioration and the seating for scores. Plugs with fractures or doubtful elements must be renewed.

Where scoring of the seating may impair the sealing, the plug should be renewed.

Test and refit

7. Test the plug internal circuit for continuity by connecting it in circuit with a 12 volt side lamp bulb and a 12 volt supply. If the bulb does not light an open circuit is indicated and the heater plug must be renewed.

CHECK BRAKE FLUID RESERVOIR

1. Check the fluid level in the fluid reservoir by observing the level in relation to the ‘MIN’ or

‘MAX’

marks on the side of the translucent reservoir.

2. If the level is below the

‘MAX’

mark clean the outside of the filler cap and top-up with new, clean fluid from a sealed container. Use only fluid recommended in the ‘General specification data’ section. Refit the cap.

ST 1088M

CHECK CLUTCH FLUID RESERVOIR

1. Clean and remove the reservoir cap and observe the fluid level in relation to the marks on the side of the reservoir.

2. Top-up if necessary with new, clean fluid from a sealed container and of a recommended specification

- section. Refit the cap.

STlOPlM

8. Ensure that the terminals are clean and that the thread at the base of the plug is free from carbon.

9. Fit the heater plugs to the engine. Do not overtigh ten.

10. Fit the heater plug lead and washer to each plug.

11. Connect the battery.

MAINTENANCE

.....

.“d c’:

^... CHECK POWER STEERING FLUID RESERVOIR

1. Clean and remove the reservoir cap and observe the fluid level in relation to the mark on the side of the reservoir.

2. If necessary top-up with a recommended fluid - see ‘General specification data’ section fluid is 12 mm

(95 in) above the filter. Refit the cap.

CHECK COOLING SYSTEM COOLANT

Refer to the ‘Cooling system’ section for details of anti-freeze and inhibitors and to the ‘General specification data’ section for anti-freeze protection quantities.

With a cold engine, the expansion tank should be approximately half full.

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

To remove the filler cap, first turn it anti-clockwise a quarter of a turn and allow all pressure to escape, before turning further in the same direction to lift it off.

When replacing the filler cap it is important that it is tightened down fuily, not just to the first stop.

Failure to tighten the filler cap properly may result in water loss, with possible damage to the engine through overheating.

BATTERY

Check Specific Gravity

T h e specific gravity of the electrolyte should be checked using a battery hydrometer. The readings should be as follows:

Temperate climate below 26.5”C (80°F) as commissioned for service, fully charged 1.270 to 1.290 specific gravity.

As expected during normal service, three-quarter charged 1.230 to 1.250 specific gravity.

If the specific gravity should read between 1.190 to

1.210, half-charged, the battery must be bench charged and the electrical equipment in the car should be checked.

Tropical climate above 26.5”C (80°F) as commissioned for service, fully charged 1.210 to 1.230 specific gravity.

As expected during normal service, three-quarter charge 1.170 to 1.190 specific gravity.

If the specific gravity should read between 1.130 to

1.150, half-charged, the battery must be bench charged and the electrical equipment on the car should be checked.

Check and Top-Up Electrolyte Level

1. Wipe all dirt and moisture from the battery top.

2. Remove the filler cover. If necessary add sufficient distilled water to raise the level to the top of separators.

Replace the filler plugs or manifold lid.

3 . Avoid the use of a naked light when examining the ceils.

4. In hot climates it will be necessary to top up the battery at more frequent intervals.

5 . In very cold weather it is essential that the vehicle is used immediately after topping up, to ensure that the distilled water is thoroughly mixed with the electrolyte. Neglect of this precaution may result in the distilled water freezing and causing damage to the battery.

Battery terminals

6 . Remove battery terminals, clean, grease and refit.

7 . Replace terminal screw; d o not overtighten. Do not use the screw for pulling down the terminal.

8. Do N O T disconnect the battery cables while the engine is running or damage to alternator semiconductor devices may occur. It

1s also inadvisable to break or make any connection in the alternator charging and control circuits while the engine is running.

9. It is essential to observe the polarity of connections to the battery, alternator and regulator, as any incorrect connections made when reconnecting cables may cause irreparable damage to the semiconducto r devices.

IMPORTANT NOTE: If a new battery is fitted to the vehicle, it should be the same type as fitted to the vehicle when new. Alternative batteries may vary in size and terminal positions and this could be a possible fire hazard if the terminals or leads come into contact with the battery clamp assembly. When fitting a new battery ensure that the terminals and leads are clear of the battery clamp assembly.

MAINTENANCE

REMEW

BRAKE SERVO

FILTER

1. Remove the nuts securing the master cylinder

2. to the servo.

Release the clip retaining the brake pipe to the clutch pipe.

3.

Separate the master cylinder from the servo.

4. Disconnect the vacuum hose from the servo.

5 . Disconnect the Lucars from the stop lamp switch at the rear of the pedal box.

6 . Remove the blanking grommets from the pedal

7. box.

Remove the split pin from the clevis and withdraw the clevis pin and washer.

ST1533M

9. Pull back the dust cover.

10. Release the end-cap.

11. Cut the filters to remove them from the shaft.

%L.

8. Remove the four nuts securing the servo to the pedal box and remove the servo.

ST1485M

12.

Clean the filter seating and fit the new filters noting that they must be cut to fit over the shaft.

13. Fit the end-cap and dust cover and refit the servo and master cylinder to the vehicle reversing the removal procedure. Use a new split pin to secure the clevis.

14. Test the brakes.

6."-

::..'.

-j

ENGINE

SLOW

RUNNING

1. Using a suitable tachometer, check the engine slow running adjustment 'see Engine tuning data'.

If

adjustment is necessary slacken the locknut and turn the control screw clockwise to increase the revolutions and anti-clockwise to decrease the engine speed. Tighten the locknut, increase the engine speed for a few seconds then re-check the slow running.

MAINTENANCE

ST1425M

2. If a tachometer is not available adjust the control screw until the slowest speed is obtained consistent with smooth and even running.

NOTE: The slow running control is the only permitted adjustment in service. Any additional adjustments required must only be carried out by authorised C.A.V. agents.

CONTENTS

Section

2.25 LITRE PETROL AND DIESEL ENGINE

2.25 LITRE PETROL AND DIESEL ENGINE CYLINDER HEAD

121

2.5 LITRE DIESEL ENGINE

-Overhaul

PETROL AND DIESEL ENGINES FAULT DIAGNOSIS

-Petrol engines

- Diesel engines

1191

FUELSYSTEM-Petrol

- & Diesel

- Tune and adjust four cylinder engine carburetter

Overhaul V$ engine carburetter - Zenith

-Tune and adjust V8 engine carburetters -

Overhaul V8 engine carburetter

- Tune and adjust V8 engine carburetter - S . U .

-Fault tracing V8 engine carburetters

- Twin tank and in-tank fuel pump installation

1191

FUEL SYSTEM

- Checking fuel injectors

- Overhaul fuel injectors

- Fitting fuel injectors

- Turbo charger -

- V8 engine cooling system

- Drain and refill four cylinder engine system

- -

- Overhaul master cylinder

- Bleed Hydraulic system

- Overhaul slave cylinder

- Clutch pedal adjustment

Page

123

125

INTRODUCTION

This Workshop Manual covers t h e Land Rover Ninety and One Ten range of vehicles. It i s primarily designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be completed within the time stated in the ‘Repair Operation Times’.

The Manual has been produced in separate books; this allows the information to be distributed throughout the specialist areas of the modern service facility.

A table of contents in Book 1 lists the major components and systems together with the section and book numbers.

The cover of each book details the sections contained within that book.

The title page of each book carries the part numbers required to order replacement books, binders or complete

Service Manuals. This can be done through t h e normal channels.

REFERENCES

To reduce repetition, operations covered in this manual do not includc refcrence to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned.

.-..--

. ’ ’

‘ 1

.--

DIMENSIONS

The dimensions quoted are to design cngineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification.

During the period of running-in from new, certain adjustments may vary from thc specification figurcs given in this

Manual. Thcsc adjustments will be re-set by the Distributor or Dealer at the After Sales Service, and thereafter should be maintained at the figures specified in the Manual.

REPAIRS ANI) REPLACEMENTS

When replacement parts are required it is essential that only Land Rover parts are used.

Attention is particularly drawn to t h e following points concerning repairs and the fitting of replacement parts and accessories:

Safety features embodied i n the vehicle may be impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer’s specification. Torque wrench setting figures given in thc Repair Operation Manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling abroad should ensure that t h e accessory and its fitted location o n the vehicle conform to mandatory requirements existing in their country of origin. The terms of t h e Owners Service Statement may be invalidated by the fitting of other than Land Rover parts.

All Land Rover parts havc the full backing of the Owners Service Statement.

Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts.

’

.. .:

...

POISONOUS SUBSTANCES

Many liquids and other substances used in motor vchicles are poisonous and should under no circumstances be consumed and should as far as possible be kept away from open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, iubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The foliowing information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. ! also outlines the other areas of risk which must not be ignored.

This intttrmation is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of your local Fire Officer. yy+-

I I

,‘

, i

. ’ I

GENERAL

PetroVgasoline vapour is highly flammable and in confined spaces is also very explosive and toxic.

When petrol/gasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is potentially very dangerous.

Always have a fire extinguisher containing FOAM CO? GAS, or POWDER close at hand when handling or draining fuel, or when dismantling fucl systems and in areas where fuel containers arc stored.

Always disconnect the vehicle battery B E F O R E carrying out dismantling or draining work on a fuel system.

Whenever petrol/gasoline is being handled, drained or stored, o r when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any head-lamps used must be flameproof and kept clear of spillage.

N O ONE S H O U L D B E PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH PETROL/

GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.

FUEL TANK DRAINING

WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST

IT IS STANDING OVER A PIT.

- -

Draining or extracting petrol/gasoline from vehicle fuel tank must bc carried out in a well ventilated area.

The receptacle used to contain the petroUgasoline must be more than adequate for the full amount of Fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placcd in a safe storagc area which meets the requirements of local authority regulations.

WHEN PETROL/GASOLINE HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK THE

PRECAUTIONS GOVERNING NAKED LIGHTS A N D JGNITION SOURCES S H O U L D BE MAJN‘I’AINED.

FUEL TANK REMOVAL

On vehicles where the fuel line is sccurcd to the fuel tank outlet by a spring steel clip, it is recommended that such clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedurc will avoid lhc possibility of residual petrol fumes in the fuel tank being ignited when the clips are released.

As an added precaution fuel tanks should have a PETROL/GASOLJNE VAPOUR warning label attached to them as soon as they are removed from the vehicle.

FUEL

TANK

REPAIR

Under no circumstances should a repair to any tank involving heat treatment bc carried out without first rendcring t h e tank SAFE, by using one of the following methods:

BOILING: With the filler cap and tank unit removed, empty the tank. Immersc the tank completely in boiling water containing an effective alkaline degreasing agent o r a detergent, with t h e water filling and also surrounding the tank for at least two hours.

After steaming o r boiling a signed and dated label to this effect should be attached to the tank.

SPECIFICATION

Purchasers are advised that the specification details set out in this Manual apply to a range of vehicles and not to any one. For the specification of a particular vehicle, purchasers should consult their Distributor o r Dealer.

The Manufacturers reserve the right to vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer’s policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the

Manufacturer nor the Distributor or Dealer, by whom this Manual is supplied, shall i n any circumstanccs be held liable fer inaccuracy the consequences ihe,-pof,

COPY RIGHT

Land Rover Limited 1984

Rover Limited, Service Department, Solihull, England.

...

I l l

Special

Service

Tools

The use of approved special service tools is important. They are essential if service operations are t o be carried out efficiently, and safely. The amount of time which they save can be considerable.

Every special tool is designed with the close co-operation of Land Rover Ltd., and n o tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools o r standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely.

Special tools bulletins will be issued periodically giving details of new tools as they are introduced.

All orders and enquiries from the United Kingdom should be sent direct to V. L.

Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where o n e exists. Countries where there is no distributor may order direct from V. L .

Churchill Limited, PO Box 3 Daventry, Northants, England "11 4NF.

The tools recommended in this Workshop Manual are listed in a multi-language, illustrated catalogue obtainable from Messers. V. L. Churchill at the above address under publication number 2217/2/84 or from

Land Rover Ltd., under part number LSM0052TC from the following address, Land Rover Publication

Service, P.O. Box 534, Erdington, Birmingham B24 OQS.

T j:z--bc

-1

DISMANTLE ANDOVERHAUL

Special tools:-

Chain wheel extractor

Tappet guide remover -

*Camshaft bearing remover

9 9

9’

”

Cork-seal guide adaptor

- guide plug

274388

531760

- reamer -

Seal guide

270304 rear main bearing

1344

Seal replacer

- rear main oil seal - - 11

Diesel engine timing gauge

R0605863

Clutch centralising tool

Whilst these tools are now not obtainable, their use is described for workshops that have them available.

Remove the engine from the vehicle. Clean the exterior and in the interests of safety and efficient working, secure the engine to a recognised engine stand.

REMOVE ANCILLARY EQUIPMENT

Before commencing, make a careful note of the position of brackets, clips, harnesses, pipes, hoses, filters and other miscellaneous items to facilitate reassembly .

Petrol engine

1. Disconnect the spark plug leads, release the distributor clamp bolt and withdraw the distributor complete. Remove the adaptor plate held by three bolts.

2. Remove the inlet and exhaust manifolds complete with carburetter. Removal of the heat shicld will facilitate this operation.

. .

Diesel engine

3. Release the fuel pipes from the injectors.

4. Rcmove the nuts securing the injector pump and withdraw the pump and the short drive shaft.

5 . Remove the induction and exhaust manifolds.

6 . Remove the six bolts and withdraw the oil filter tube (carly engincs only). At the same time remove the two joint washers and the baffle plate with the timing pointer attached. D

NOT disturb the two bolts retaining the timing pointer. Later engines have a single plate with timing pointer.

7. Remove the vacuum pump.

2.25 LITRE PETROL AND DIESEL ENGINE 12

Petrol and diesel engines

8. Remove the six bolts and withdraw the rear side cover complete with fuel pump.

9. Remove the alternator and drive belt.

10. Remove the fan and pulley.

11. Remove the seven -bolts- and remove the water

12. pump.

Drain the sump and remove t h e dipstick.

13. Remove the starter motor.

14. Restrain the flywheel, remove the crankshaft pulley nut and withdraw the pulley. (Bolt on later engines).

15. Evenly slacken and remove t h e clutch retaining bolts and withdraw the clutch assembly and centre plate.

Remove the two bolts and remove the oil filter assembly complete from the cylinder block.

Remove the bowl retaining bolt, drain the oil and discard the element.

Remove the cylinder head.

REMOVE AND OVERHAUL OIL PUMP

1. Remove the sump.

2. Bend back the lock washers and remove the two bolts securing the oil pump to the crankcase.

Withdraw the oil pump complete with strainer and oil pump drive shaft. continued

1121 2.25 LITRE PETROL AND DIESEL ENGINE

Dismantle oil pump

3. Bend back the lock washer and release the nut securing the strainer to the oil pump body and remove the strainer and sealing ring.

4. Removc four bolts and washers and lift off the oil pump cover and lift out the driven and idler gears.

(a) driven gear

(b) idler gear

5 . Remove the oil pressure relief valve plug and sealing washer. Withdraw the relief valve spring, plunger and ball.

7. Clean the pump body and assemble the gears.

Place a straight edge across the pump body face, as illustrated, and using a feeler gauge, measure the clearance between the body and gears. The correct clearances are as follows:

8. Idler gear 0,07 to 0,15 mm (0.003 to 0.006 in).

9. Driven gear 0,05 to 0,12 mm (0.002 to 0.005 in).

10. Gears must be renewed in pairs. A worn, but serviceable gear, must not be matched with a new one.

11. If necessary renew idler gear spindle by drilling-out the peened over end of t h e spindle so that the spindle can be withdrawn from the pump body. T

O ensure squareness when fitting t h e new spindle, asscmble it into the pump body with the two gears.

Fit the cover and secure with the four bolts.

Support the pump body and peen over the end of the new spindle. Remove the cover and gears and check security of the spindle.

12. If worn, remove the idler gear bush and press in a replacement. Drill the lubrication hole 3,17 mm

(0.125 in) and ream the bush to i2,7 mm (0.500 in) diameter. continued

Overhaul the oil pump

6. Examine the gears for wear, scores and pits. If the gears appear serviceable check for end-float as follows:

ST911M

2.25 LITRE PETROL AND DIESEL ENGINE

?. 13. A scored ball valve seat can be restored by using a locally made lapping tool by silver soldering a new ball (part number 3748) onto a length of suitable tube.

14. Install the tube in a drill and lap-in using coarse grinding paste. Finally hand-lap the seat with fine paste using the same diabalo method as for lapping valves.

15. Thorougly wash the pump body to remove all traces of grinding paste.

REMOVE AND OVERHAUL THE TIMING CHAIN,

SPROCKETS AND TENSIONER

1. Remove the timing cover. Before removing the timing chain tensioner notc the ratchet position in relation to t h e pawl which will give an indication of chain wear. If the last tooth of the ratchet is engaged with the pawl t h e chain is excessively worn and should be discarded.

2. Remove the ratchet pivot bolt, plain bolt and n u t and withdraw the timing chain tensioner complete.

3. Remove the timing chain and crankshaft sprocket.

4. Remove timing chain damper.

ST694M

Assemble the oil pump

16. Fit the idler gear to the spindle.

17. Fit the driven gear with plain part of the bore uppermost. See illustration after instruction 9.

18. Smear the joint face of the body with jointing compound and fit the cover over the dowels and secure with the four bolts and spring washers.

19. Hold relief valve bore vertically and insert the ball followed by the plunger with the ball seat end first.

Fit the spring, sealing washer and plug.

20. Fit the oil strainer sealing ring to the pump body followed by the lock washer and strainer. Tighten the strainer retaining nut so that when fitted the strainer is positioned parallel to the sump baffle plate. Secure t h e nut with the lock washer tab.

Later engines are fitted with a bracket to locatc the strainer.

5 . Remove the camshaft sprockct retaining bolt and washer. Withdraw the sprockct using chain wheel extractor 507231 or similar.

Illustration A shows the early retaining bolt and tab washer.

Illustration B shows the latest bolt and special washer.

ST696M conriniicd

12 2.25 LITRE PETROL AND DIESEL ENGINE

REMOVE TAPPETS, ROLLERS AND GUIDES

ST697M

1 . Remove the eight tappet guide locating bolts from the right-hand side of the cylinder block.

CAUTION: Do not remove the tappet guides before the rollers otherwise the rollers may fall behind the camshaft.

2. Using long nosed pliers or a suitable bent length of wire lift out the tappet slides and identify them with their respective guides for possible refitting.

6. Examine the sprockets and discard if the teeth are

7. worn.

Dismantle the tensioner assembly and discard any worn parts. In particular check the condition of the ratchet and pawl. Check the tension of the spring by comparing it with a new one. Examine t h e jockey wheel teeth for wear, and renew bush if worn.

Key to tensioner assembly

1. Piston assembly

2. Cylinder assembly

3 . Cylinder spring

4. Ball

5 . Ball retaining clip

6. Ratchet and spring

7. Ratchet pivot bolt

8. Pawl

9. Jockey wheel

10. Timing chain damper

8. Assemble the tensioner as illustrated and compress the assembly ready for fitting t o the engine.

3. Lift out the tappet rollers and mark the side facing the front of the engine for possible reassembly.

4. Lift out the tappet guides and retain with their respective slides and rollers. If the guides are difficult to remove use special tool 530101A.

5 . Carefully examine all parts and discard any that are worn or damaged. f?

. 4

ST699M

..::.::. ..

2.25 LITRE PETROL AND DIESEL ENGINE 12

RENEW TIMING COVER OIL SEAL

1. On initial assembly of the engine the mud shield around the oil seal is rivetted in position but after removal in service the rivets are substituted with self tapping drive screws.

2. Drill out the rivets securing the oil seal mud shield.

3 . Press out the oil seal and clean the mating surfaces.

4. Smear the outside diameter of a new oil seal with

Hylomar P L 32-M jointing compound. Press the oil seal into the timing cover, lip side facing crankshaft.

5. Coat the drive screws with Hylomar and secure the mud shield.

REMOVE THE CAMSHAFT

1. Remove the skew gear bush retaining scrcw and lift out the skew gear bush assembly. Also withdraw the distributor pump (diesel) or ignition distributor

(petrol engine) drive coupling with the skew gcar assembly.

ST596M

’// I I

2. Since the camshaft sprockct has already been removed, bend back the lock tabs, remove the two bolts and the camshaft thrust plate. Carefully withdraw the camshaft.

NOTE: Lock tab washers are not used on later engines

ST7OOM

Inspect the camshaft

3.

Discard the camshaft if any of the following visual defects are evident.

4. Scored, worn, pitted or chipped cams. Worn, corroded and discoloured journals. Worn and chipped gear teeth.

2.25 LITRE PETROL AND DIESEL ENGINE

5 . Check the journals for wear and if more than

0,050 mm (0.002 in) the shaft should be renewed.

6. Rest the camshaft between 'V' blocks and check for run-out with a dial indicator. If run-out is in excess of 0,050 mm (0.002 in) the shaft should be straightened or renewed.

Renew the ring gear

7. Drill a 8,0 mm (A in) hole between the root of any two teeth and the inner diameter of the starter ring deep enough to weaken the ring. Do not allow the drill to enter the flywheel.

8. Secure the flywheel in a soft jawed vice and cover it with a cloth to protect one from personal injury.

Place a cold chisel above the drilled hole and strike it sharply t o split the ring gear.

REMOVE AND OVERHAUL THE FLYWHEEL

1. Remove the flywheel retaining bolts and withdraw the flywheel and reinforcing plate.

\ "

2. Wear or scores on the flywheel clutch face can be corrected by machining provided that the overall width of the flywheel is not reduced below the following dimensions:

Petrol engines 34,?2 mm (1.37'5 in).

Diesel engines 36,96 mm (1.453 in).

3. Check that the flywheel has not been previously machined.

4. Examine the ring gear teeth and if chipped or worn the gear can be renewed.

Reface the flywheel

5 . Remove the clutch location dowels.

6, i"$itcii;ne fly.wheei the compieic face removing only the minimum material necessary to achieve a smooth flat surface parallel with the crankshaft mating face and within the above width dimensions and fit new dowels.

S T 928M

9. Heat the new ring gear uniformally to between

225°C and 250°C but do not exceed the higher figure.

10. Place the flywheel, clutch face down, on a flat surface and locate the heated flywheel with the square edge of teeth downward towards the flywheel clutch face and chamfered edge of the teeth uppermost. This applies to both petrol and

Diesel engines.

11. Press the starter ring firmly against the flange until the ring contracts sufficiently to grip the flywheel. g??;:

5 .

Allow the ring gear to cool naturally. Do not %i-.' hasten cooling in anyway.

2.25 LITRE PETROL AND DIESEL ENGINE

112

REMOVE THE CONNECTING-RODS AND PISTONS

During the following instructions it is important that all components are kept in related sets and the pistons arc identified with their respective bores.

1. Turn the crankshaft to bring the connecting-rod caps to an accessible position and remove each cap and lower shell in turn. Note that the connecting- rod caps are numbered one to four.

REMOVE, INSPECT

CRANKSHAFT -

AND OVERHAUL

1. Remove the eight bolts securing the flywheel housing to the cylinder block and remove the housing and rear main bearing oil seal, and ‘0’ ring.

2. Push each piston asscmbly up the bore and withdraw from the cylindcr block. Assemble the caps and shell.? to the connecting-rods and place to one side for inspection with the cylinder block at a later stage.

ST718M

2. Remove the main bearing caps and shells and lift out the crankshaft. Collect the bearing shells from the bearing saddles and the thrust washers from thc centre saddle. continued

1121 2.25 LITRE PETROL AND DIESEL ENGINE

Inspect crankshaft

3. Degrease the crankshaft and clear out the oil ways, which can become clogged after long service.

4. Examine visually, the crankpins and main bearing journals, for obvious wear, scores, grooves and overheating. A decision at this stage should be made as to whether t h e condition of the shaft is worth continuing with more detailed examination.

5. With a micrometer, measure and note the ovality and taper of each main bearing journal and crankpin as follows:

6. Ovality each other at various intervals.

The maximum ovality must not exceed 0,040 mm

(0.0015 in).

7. Taper at both ends of the main bearing journal and crankpin. The maximum permissable taper must not exceed 0,025 mm (0.001 in).

8. To check for straightness, support the front and rear main bearing journals in ‘V’ blocks and position a dial indicator to check the run-out at the centre main bearing journal. Run-out must not exceed 0,076 mm (0.003 in) taking i n t o account any ovality in the centre journal.

The overall allowable wear limit should not exceed

0,11,4 mm (0.0045 in) for main bearing journals and 0,088 mm (0.0035 in) for crankpins.

A crankshaft worn beyond the limits of maximum taper, ovality and overall wear can be ground undersize for which bearing shells arc available see data, book 1.

When grinding the crankshaft main bearing and crankpin journals, rotation of the grinding wheel and crankshaft must be i n the same direction, anti-clockwise, viewed from the flywheel end of the crankshaft. Final finishing of the journals should be achieved by using a static tapping stone with the crankshaft rotating in a clockwise direction viewed from t h e flywheel end of the crankshaft. It is important to ensure that, when grinding, the stone travels beyond the edge of the journal ‘A’ to avoid formation of a step ‘R’ as illustrated. Also care must be taken not to machine or damage the fillet radii.C.

Inspect cylinder bores

2. Mcasure the cylinder bores for ovality, taper and general wear, using any suitable equipment.

However, an inside micrometer is best for checking ovality and a cylinder gauge for taper.

3 . Check the ovality of each bore by taking measurement at the top of the cylinder just below the ridge at two points diametrically opposite. The difference between the two figures is the ovality of the top of the bore. Similar measurements should be made approximately 50 mm (2.0 in) up from the bottom of the bore so that the overall ovality may be determined.

4. The taper of each cylinder is determined by taking measurements at t h e top and bottom of each bore at right angles to t h c gudgeon pin line. The difference between the two measurements is the taper.

5 . To establish maximum overall bore wear, take measurements at as many points possible down the bores at right angles to the gudgeon pin line. The largest recorded figure is the maximum wcar and should be compared with t h e original diameter o f the cylinder bore.

Maximum permissible ovality 0,127 mm (0.005 i n ) .

Maximum permissible taper 0,254 mm (0.010 in).

Maximum permissible overall wear 0,177 mm

(0.007 in). con t

I n ued pi

ST1808M

EXAMINE AND OVERHAUL

BLOCK

THE

CYLINDER

1. Degrease the cylinder block and carry out a thorough visual examination checking for cracks and damage. To check the main bearing caps and saddles for distortion. Fit the main bearing cap without bearing shells and tighten to the correct torque. Slacken and remove the bolt on one side of each bearing cap and check with a feeler gauge that no clearance exists at the joint face between the cap and saddle.

T t

.." If the above figures are exceeded the cylinders must be rebored o r sleeved depending upon the general condition of the bores and amount of wear.

Alternatively, if the overall wear, taper and ovality are well within the acceptable limits and the original pistons are serviceable new piston rings may be fitted. It is important however, that the bores are deglazed, with a hone, to give a cross- hatched finish t o provide a seating for the new rings. It is vital t o thoroughly wash the bores afterwards to remove all traces of abrasive material.

Inspect camshaft bearings

9. Measure the internal diameter of each camshaft bearing a t several points using an internal micrometer. A comparison of the bearing diameters with those of the respective camshaft journals will give the amount of clearance. The bearings should be renewed if the clearance exceeds 0,0508 mm (0.002 in). Or, in any event, if they are scored or pitted.

Fit cylinder sleeves

Cylinder bores that cannot be rebored can be restored by fitting sleeves to enable standard size pistons to be fitted. Sleeving one cylinder only will distort the adjacent bore so sleeving must be carried out in pairs, i.e. cylinders 1 and 2 o r 3 and 4.

6. Machine the cylinder bores to accept the sleeves to

94,425

0,012 mm (3.7175

0.0005 in). This will give the sleeve a 0,076 to 0,114 m m (0.003 to

0.0045 in) interference fit.

7. Press the sleeves squarely into the bore using a pressure of t w o t o three tons. Exccssive pressure could damage the sleeve and cylinder block. The sleeves must not be proud of the cylinder block top face or more than 2,5 m m (0.10 in) below the surface.

8. Borc and hone the sleeves to accommodate the pistons with the required clearances, see piston and connecting-rod examination.

2.25 LITRE PETROL AND DIESEL ENGINE 12

RENEW CAMSHAFT BEARINGS

The following special tools for this operation are no longer available from the suppliers. However, the operation is nevertheless described for workshops that have these tools in stock. If tools are not obtainable the work should be entrusted to line-boring specialists.

605975 Bearing drift and adaptor assembly comprising:

274388 Bearing drift and

531760 Adaptor.

274389 Reamer for bearings which includes:

274394 Guide plug.

1. Remove t h e rear bucket type plug and using special tool 274388 drift out the front and rear bearings and withdraw them through the side cover apertures.

2. With the same tool, drift the two centre bearings into the distributor drive chamber and collapse them to assist withdrawal. continued

2.25 LITRE PETROL AND DIESEL ENGINE

NOTE: The two centre and rear bearings are of the same width, whereas the front bearing is wider and has an additional oil feed hole. Also ensure that before fitting the bearings the oil passages leading to the bearings are free of sludge and dirt.

3. Position the cylinder block vertically, rear face down.

4. Place a new bearing into the front camshaft chamber and position it so that it is above the second bearing housing, counting from the front of the block.

5 . The chamfer on the bearing edge must be towards the housing bore.

6. Align the oil hole in the bearing with the innermost oil feed drilling in the housing bore. Accuracy is essential otherwise misalignment of the oil holes may result and once the bearing is in place it cannot be rotated to correct any error.

7. Add pencil marks to the bearing outer diameter and the cylinder block adjacent to the housing to assist in checking alignment.

8. Having visually aligned the bearing, place inside it the special adaptor 531760.

9. Maintain the bearing in a level position. Pass the drift through the front bearing housing into the camshaft chamber so that it rests on top of the adaptor. Commence drifting the bearing into the block. Ensure that the bearing is not drifted in too far, and that the oil feed'holes are correctly aligned.

10. Repeat the above instructions for the front bearing. Note that the front bearing is wider and has a small hole in addition to the large oil feed hole. This small hole aligns with a vertical drilling in the block, which in turn feeds a horizontal drilling for the tappet mechanism. Drift this bearing in so that the outer edge is just below the machined surface of the front face. This is to ensure that when the camshaft thrust plate is fitted it will not stand proud on the bearing edge. -

111 \\\, lillllllilll

11. Turn the cylindcr block over so that the rear face is uppermost and repeat the foregoing procedures for the two remaining camshaft bearings.

The bearings must now be reamed to size as follows: N o lubricant is necessary for this operation since t h e best results are obtained when the bearings are cut dry.

12. Locate the guide plug 274394, into the front camshaft bearing and retain using the thrust plate screws, but do not tighten the screws at this stage.

13. Insert the reamer 274389 from the rear of the cylinder block, locating it through the guide plug at the front.

14. Locate the guide collar immediately in front of the rcamer cutter into the rearmost bearing, then secure the screws retaining the guide plug at the front.

15. Position the cylinder block vertically, rear face uppermost and ream the rear and two centre bearings. As each bearing is cut the reamer should be held steady by the operator whilst an assistant, using a high pressure airline, blows away the white metal cuttings, before allowing the reamer to enter the next bearing.

16. Remove the guide plug 274394 and ream the front bearing.

17. Remove the reamer handle and bolt and withdraw the reamer, turning it in the same direction as tor cutting.

18. Remove the plugs from the ends of oil gallery passage and clean the gallery and oil feed passages to camshaft and crankshaft bearings, using compressed air. Refit the plugs and lock in position. continued

?$: .'?

. + d z ,

k - v

2.25 LITRE PETROL AND DIESEL ENGINE

112

19. The hexagon-headed plugs at the rear of the block should have new washers fitted, and their threads coated with a suitable jointing compound.

20. Thoroughly clean the cylinder block preferably using an airline to remove all traces of metal cut t ings .

Check crankcase main bearings

21. Discard scorcd, pitted, cracked and worn bearing shells.

22. To determine the maximum wear, assemble the main bearing shells and caps to the crankcase and tighten the bolts to t h e correct torque figure.

23. Using an inside micrometer, measure each bearing at several points and note the greatest figure. The maximum wear is the difference between this figure and the smallest diamcter of the corresponding crankshaft journal. The main bearing running clearance is in the data section.

24. The bearing clearances may also be determined by using ‘Plastigauge’. Since this method requires the crankshaft to be fitted to the crankcase, the procedure is described under engine assembly.

PISTON AND CONNECTING-ROD INSPECTION

The following checks relating to pistons and rings must also be carried out prior t o fitting new pistons to rebored and sleeved cylinder blocks.

Until it is decided if new components are required all parts must be kept in their related sets and the position of each piston to its connecting-rod should be noted.

1. Remove the piston rings and gudgeon pin from each piston and dctach the connecting-rod.

ST708M

2. Original pistons - coi?;poiiefi:s aiid cairj ou: a vimal examinatim cf the pistons and rings and discard any which are unserviceable. Pistons which appear serviceable should be subjected to a more detailed examination described under ‘New Pistons’. continued

lcl

2.25 LITRE PETROL AND DIESEL ENGINE

3. New Pistons - engines at the factory are specially graded to facilitate assembly. T h e grade letter on the piston crown should be ignored when ordering new pistons. Genuine Land Rover service standard size pistons are supplied 0,025 mm (0.001 in) oversize to allow for production tolerances on new engines.

When fitting new pistons to a standard size cylinder block the bores must be honed to accommodate the pistons with the correct clearances. In addition

Land Rover pistons are available 0,50 and 1,Ol mm

(0.020 and 0.040 in) oversize for fitting to rebored cylinder blocks.

Clearance limits for new standard size pistons in a standard cylinder bore measured at right angles to the gudgeon pin are in the “General specification data” section.

When taking the following measurements t h e cylinder block and pistons must be at the same temperature to ensure accuracy.

NOTE: The illustration shows a petrol engine piston but the method is the same for the Diesel engine.

4. Using a suitable micrometer measurc the pistons at thc bottom of the skirt at right angles to the gudgeon pin.

5 . With an inside micrometer or cylinder gauge measure the diameter of the bore at approximatcly half-way down and note the reading.

6. The clearance is determined by subtracting the piston diameter from the bore diameter.

NOTE: Eariy 2.25 Diesel pistons have a piston ring groove below the gudgeon pin. This has been deleted on later engines.

If

gauge equipment is not available the clearance can be assessed by placing a long, suitably sized, feeler gauge down t h e thrust side of the bore and inserting the appropriate piston, ‘upside down’, in the bore and position it with the gudgeon pin parallel to the crankshaft axis. Push the piston down the bore and stop at the tightest point and whilst holding the piston still, slowly withdraw the feeler gauge. If a steady resistance of approximatcly 2,5 kg (6 Ibs) is felt, the clearance is satisfactory,

Inspect piston rings

Normally when an engine is being overhauled the piston rings are discarded unless the pistons have been removed for a different purpose and the engine has only completed a small mileage. Before refitting the piston the rings should be examined for wear and damage. In addition the rings must be checked for side clearance in the pistons and gap in the bores. The latter two checks must be made when fitting new rings to new and used pistons.

8. Check gap When checking thc ring gap in worn bores, but are nevertheless within the acceptable taper and ovality limits, the ring must be inserted squarely into the bottom of the bore at the lowest point of the piston travel. To ensure squareness of the ring push the ring down the bore to the correct position with a piston. With newly machined bores, the ring may be inserted squarely into any position in the bore.

9. Using an appropriate feeler gauge check the gaps of all the rings, in turn, including the oil control ring assembly.

The correct gaps are listed in the Data Section. If any gap

I S less than that specified, remove the ring, and file the ends square, whilst holding the ring in a filing jig or vice. Should any gap be excessively wide and not likely to close-up to within the specified limits when hot, an oversize ring should be fitted.

4“‘.

&--.. y;;; continued

2.25 LITRE PETROL AND DIESEL ENGINE 12

Side clearance data

Compression rings - to 0,097 m m (0.0018 to

0.0038 in).

Oil control ring - to 0,089 mm (0.0015 to

0.0035 in).

Side clearance - d i e d engine

Compression rings - to 0,11 m m (0.0025 to

0.0045 in).

Oil control ring

0.0025 in).

- mm (0.0015 to

Check piston ring side clearance

Petrol engine pistons have two compression rings and one oil control ring assembly. The diesel engine has three compression rings and one oil control ring assembly. The method of checking clearances are the same for both engines but the clearances are different.

It is important that clearances are correct. Rings that are too tight will bind when hot, imparing the radial pressure causing possible loss of compression.

Excessive clearance will allow the rings to rock in the grooves and the resulting pumping action could cause excessive oil consumption and eventually broken rings.

10. Diesel engine pistons - the bottom groove (not groove in skirt). Fit the two unpolished rings with the word ‘TOP’ uppermost to the middle two grooves. Insert to polished chrome ring with the internal chamfer t o the top groove with the word ‘TOP’ uppermost.

A ring groove is provided at the bottom of the diesel engine piston skirt for the fitment of an oil

11 control ring in cases of excessive oil consumption on high mileage engines (early engines only).

Petrol engine pistons - oil control ring to the bottom groove. Fit the unpolished compression ring with the word ‘TOP’ uppermost to the second groove. Insert the polishcd chrome ring with an internal chamfer and the word ‘TOP’ uppermost to the top groove.

12. After fitting each ring, roll it around thc piston groove to ensure that it is free and does not bind.

13. Using an appropriate feeler gauge check the clearance between the rings and piston grooves.

Clearances in excess of 0,106 to 0,152 mm (0.004 to

0.006 in) are unacceptable and the ring and o r the pistons shouid be renewed.

NOTE: Whilst the illustration shows a Diesel piston the method for the petrol is the same.

Inspect gudgeon pins

14. Check the gudgeon pin for wear, cracks, scores and overheating.

15. The gudgeon fit in the piston must be a tight push fit at a temperature of 68°F (20°C). Check the gudgeon pin for ovality and taper using a micrometer.

Connecting-rod inspection

Check the connecting-rods and caps for distortion as follows; fit the correct cap, less the bearing shells, to each connecting rod as denoted by the number stamped near the joint faces. This number also indicatcs the crankshaft journal to which it must be fitted.

Tighten the nuts to the correct torque and release the nut on one side only. Check, with a feeler gauge, that no clearance exists between the joint faces. i f there is a gap the connecting-rod is distorted and should be renewed. continued

2.25 LITRE PETROL AND DIESEL ENGINE

ST716M

As an alternative, the bearing clearances can be determined by using ‘Plastigauge’ which consists of a thin piece of plastic material a few hundreds of a millimeter o r thousands of an inch in diameter.

When the material is flattened by being squeezed between the bearing and crankpin the width of the plastic is measured by a scale gauge which indicates the clearance.

23. Wipe any oil from the crankpins and place a piece of ‘Plastigauge’ across the centre of the bearing in the connecting-rod cap. Assemble the rod to the appropriate crankpin and tighten to the correct torque. Do not rotate the connecting-rod or crankshaft during this operation.

24. Remove the connecting-rod cap and bearing shell and using the scale supplied measure the flattened

‘Plastigauge’ at its widest point. The graduation that most closely corresponds to the width of the

‘Plastigauge’ indicates the bearing clearance.

The correct clearance with new or overhauled components is 0,019 to 0,063 mm (0.0007 to

0.0025 in).

25. Wipe off the ‘Plastigauge’ with an oily rag. D

O not scrape off otherwise it may damage the crankpins. c:!

18. Use an accurate connecting-rod alignment gauge to theck the rods for bend and twist. The maximum allowable for both conditions must not exceed

0,127 mm (0.005 ins).

19. Examine and check t h e small-end bush for wear. If necessary renew the bush. The correct clearance of the gudgeon pin in the small-end bush is given in

“General specification data”.

20. When renewing a bush ensure that the oil hole in the bush lines up with the hole in the connecting-

21. rod. Finish the bush to t h e correct size and clearance.

Connecting-rod bearings that are worn, pitted, scored and show signs of overheating must be discarded. If more than one of the bearings show these signs they must all be replaccd. When fitting new or used bearings t o reground (petrol engines only) o r serviceable crankpins the clearances must be checked.

Connecting-rod bearing nip and clearance

New bearing halves are supplied with a protective coating and must be degreased before fitting.

22. Fit the bearing halves t o the connecting-rod and cap and secure the assembly with thc correct torque. Slacken the nut on one side only and check the clearance between the joint faces with a feeler gauge. The clearance should be between 0,lO and

0,20 mm (0.004 and 0.008 in). The bearing nip can be adjusted by the selective assembly of the bearing shells which are available in slightly varying thicknesses. Do not file or machine the caps or rods to vary the bearing nip, Make a final check t o prove the clearance by inserting a 0,063

(0.0025 in) shim paper between the crankpin and one half of the bearing and tightening to the correct torque. The connecting-rod should resist rotation and move freely with the shim paper removed.

23 end--oat

26. Fit the connecting-rods complete with bearings to their respective crankpins. Move the connecting- rod to one side and check the clearance, with a feeler, on the opposite side. The correct clearance is between 0,20 and 0,30 mm (0.007 and 0.012 in). continued

. .

./.

...

:,,,;,

... .

Assemble pistons to connecting-rods

27. Petrol engine pistons can be fitted either way round, except those that are being refitted to their original bores in which case they must be fitted to the connecting-rod in the same position in accordance with the mark made during removal.

28. Inscrt a circlip in one side of the gudgeon pin boss and assemble the piston to the connecting-rod with t h e gudgeon pin. Secure the assembly with a circlip on the opposite side of the piston.

29. Diesel engine pistons must only be fitted one way in relation to the connecting-rod. The piston must be assembled with t h e point of the ‘V’, on the piston crown, on the same side as the lubrication hole in the connecting-rod. Assemble the piston to the connecting-rod in the same manner as for the petrol engine.

Place the piston and connecting-rod assemblics to one side ready for fitting to the cylinder block. It is good practice to renew thc connecting-rod bolts

2.25 LITRE PETROL AND DIESEL ENGINE

ASSEMBLE ENGINE

FIT CRANKSHAFT

Main bearing nip and clearance

New main bearing halves are supplied with a protective coating and must be degreased beforc fitting.

1. Fit the bearing halves in the crankcase saddlcs and caps and secure the caps to the crankcase and tighten to the correct torque. Slacken the bolts on one side of the caps only and, with a feeler gauge, check t h e gap between the joint faces. ‘The clearance or nip must be within 0,lO to 0,15 m m

(0.004 to 0.006 in). T h e bearing nip can be adjusted by selective assembly of the bearing halves available in varying thicknesses. Do not file or machine thc caps or saddles to achicvc the corrcct clearance. Note that the rear main bearings are wider than thc rcmaining four.

2. T o make a final check that the clearance is correct, leave the bearing halves in the crankcase saddles and carefully lower the crankshaft into position.

Check each bearing in turn by inserting a 0,063 m m

(0.0025 in) shim paper between the bearing cap and crankshaft journal and tighten the bolts to thc correct torque. If the clearance is correct, there should be a slight increase in t h c rcsistancc to rotation of the crankshaft.

. I ’ .

.... ..

ST722M

As an alternative ‘Plastigauge’ may bc used to check the clearance in the same manner as with the connecting-rod bearings. This material may also be used to determine the amount of wear in used bearings and j o t ” . continued

2.25 LITRE PETROL AND DIESEL ENGINE

~~ ~~

3. Locate the crankshaft in position on the upper bearing halves in the crankcase and wipe any oil from the journals since ‘Plastigauge’ is soluble in oil. Place a piece of ‘Plastigauge’ across the lower half of each crankshaft journal o r lower bearing cap shell. Fit the cap and tighten to the correct torque. Remove the cap and bearing and using the scale supplied with the ‘Plastigauge’ measure the flattened ‘Plastigauge’ at its widest point. The graduation that most closely corresponds with the width of the ‘Plastigauge’ indicates the bearing clearance.

The correct clearance with new o r overhauled components is included in “General specification data” section. If new bearings are being fitted use selective assembly to obtain the correct clearance.

Wipe off, not scrape the ‘Plastigauge’ with an oily rag from the journals o r bearings.

5. Place the crankshaft in position in the crankcase and mount a dial test indicator to read-off the end of the crankshaft. A feeler gauge may be used instead of an indicator.

6. Determine the end-float by moving the crankshaft away from the indicator and zero the dial. Move the crankshaft in the opposite direction and notc the indicator reading. Alternatively measure the clearance with a feeler gauge. The end-float should be 0,05 to 0,15 mm (0.002 t o 0.006 in).

7. If adjustment is required substitute with oversize thrust washers. Variation of thrust washer thickness at each side of crankshaft journal must not exceed 0,08 mm (0.003 in) to ensure that the crankshaft remains centralised. eL? w3

Adjust crankshaft end-float

4. Lift out the crankshaft and insert a standard size thrust washer both sides of fhe centre main bearing saddle with the grooves towards the crankshaft.

8. Lubricate the crankshaft main journals with clean engine oii and fit the appropriate bearing caps and lower shells to the crankcase with the exception of number five main bearing. Ensure that the caps locate properly over the dowels. Using new bolts and washers evenly tighten t o the correct torque figure. continued

2.25 LITRE PETROL AND DIESEL ENGINE 12

. .

10. To prevent any cork seal material becoming trapped between t h e bearing cap and crankcase, chamfer the inner edge of the corks 0,40 to

0,80 mm

(id to &in) wide as illustrated.

Immerse the cork seals in engine oil and fit them to the bearing cap.

Fit rear main oil seal

13. Check that the crankshaft oil seal journal is undamaged and clean. Make sure the seal housing is clean and dry and free from burrs. Do not touch the seal lip and ensure that the outside diameter is clean and dry. The P.T.F.E. Seal Part N o ETC

5369 which should be used, is supplied with a former to maintain t h e correct shape and must not be removed until the seal is to be fitted.

14. Using special seal replacer 18G 134-1 1 and with the lip side leading drive-in the scal as far as the tool allows. If t h e tool is not availablc fit the seal to the bottom of the housing to ensure squareness.

1 I . Fit the bearing cap and lower shell to the crankcase and secure with new bolts and washers and tighten to the appropriate torque.

12. To allow for shrinkage after fitting leave t h e cork seais standlng proud of the crankcase-sump face. If possible delay the fitting of the sump for approximately twelve hours and leave the seal protruding 2,40 mm (& i n ) and then place a

6,350 mm ( % in) washer over the seal and cut off the surplus. If it is necessary to fit the sump

2.25 LITRE PETROL AND DIESEL ENGINE

15. Fit the '0' ring seal t o the flywheel housing.

16. Examine the seal guide number 18G 1344 and repair any damage that could destroy the seal lip.

17. Lubricate the outside diameter of the seal guide and the seal journal with concentrated 'Oildag' i n a

25% solution with clean engine oil.

18. Place thc seal guide on the crankshaft flange and, using the two dowels protruding from the cylinder block rear face as a guide to ensure initial squareness, fit the flywheel housing and remove the seal guide. Secure the flywheel housing evenly tightening the retaining bolts.

5. Lubricate the cylinder walls, piston rings and crankpins. Compress the piston rings with a suitable compressor tool and carefully lower the connecting-rod into the bore ensuring that the oil spray hole faces the camshaft side of the engine.

With diesel engines the point of the arrow headed valve clearance indentation in the piston crown, and the oil spray hole must face the camshafi side of the engine.

6. Using a soft mallet, sharply tap thc piston into the bore so that the whole of the piston is just bclow the surface of the cylinder block.

FIT THE CONNECTING-RODS AND PISTONS

1. Turn t h e crankshaft to position numbers one and four crankpins at bottom dcad centre to facilitate fitting the connecting-rods.

2. When fitting the connecting-rods and pistons ensure that the bolts do not foul and damage the crankpins. As a precaution i t is recommended that rubber or soft plastic sleeves are placed over the threads.

3 . The connecting-rod bolts have eccentric heads which locate in a recess i n the connecting-rod. I t is essentia! that the head of each new bo!t is proper!y located before tightening.

4. Stagger the compression rings so that the gaps are equidistantly spaced round the piston but, so arranged, that no gap is positioned on the thrust side of the piston i.e. opposite the camshaft. Turn the oil control ring so that the gap is in line with the gudgeon pin.

ST731 M

7. Check that the bearing shell is properly located in the connecting-rod and pull the rod onto the crankpin. Locate t h e bearing shell correctly and f i t the cap so that the identification numbers are together on the camshaft side of thc engine. Fit and tighten new nuts to the correct torque figure.

Repeat the foregoing instructions for fitting the remaining piston and connecting-rod assemblies. r-. r f :

I:. e

2.25 LITRE PETROL

AND

DIESEL ENGINE

FIT THE CAMSHAFT

1. Lubricate the camshaft bearings and with care, insert the camshaft into the cylinder block.

Temporarily secure a new thrust plate with the two bolts.

FIT TAPPETS, GUIDES AND ROLLERS

1. If the same parts are being refitted ensure that they are returned to their original positions. Ensure that the tappct slides move freely in the guides.

2. Insert the tappet guides into the cylinder block and align the locating screw holes.

3. Fit the tappet rollers ensuring that they are fitted in accordance with the marks made during removal.

New rollers, however. may be fitted either way round.

4. Before fitting the tappet slides make sure the oilways are clear to t h e tappet bearing surface, the cross drilling and the oil feed to the push rod.

5 . Insert t h e tappet slides w i t h the word 'FRONT' towards the front of the engine.

6. Secure the tappet guides with NEW Micro encapsulated screws and tighten to thc correct torque figure. Micro encapsulated screws should also be used on engines where the screws were originally wired for security.

. .

2. To check the camshaft end-float, f i t the woodruff key and temporarily f i t the camshaft chain wheel and mount a dial test indicator, as illustrated, so that the stylus rests in a loaded condition upon the machined face of the cylinder block. Zero the dial and move the camshaft back and forward and note the reading. The end-float should be within 0.06 to

0,13 nim (0.0025 to 0.0055 in). If the end-float is outside these limits, f i t different thrust plates until the correct tolerance is achieved.

3. Removc the test indicator and chain wheel and secure the thrust plate with the two bolts and tab washers. (Tab washers ommitted on later engines).

- .,

2.25 LITRE PETROL AND DIESEL ENGINE

FIT THE FLYWHEEL

1. Examine the flywheel and crankshaft mating faces and remove any burrs or imperfections that could prevent the flywheel locating correctly. Check that the dowel is in position.

2. Offer up the flywheel t o the crankshaft and secure with the reinforcing plate and retaining bolts,

Evenly tighten the bolts to the correct torque figure.

3. To check the flywheel run-out, mount a dial test indicator so that the stylus rests, in a loaded condition, on the clutch pressure face at a radius of

114 mm (4.5 ins).

4. Turn the flywheel, and check that the run-out does not exceed 0,05 t o 0,07 mm (0.002 to 0.003 in).

Should the run-out be excessive, remove the flywheel, and check again for any irregularities on flywheel and crankshaft mating faces and dowel.

ST 927M

_--.

Diesel engine

3. Turn the crankshaft in a clockwise direction until the E.P. mark o n the flywheel is in line with the pointer on the flywheel housing. T h e pointer on later engines has been omitted but can be obtained from Land Rover spares stockists under part number E R C 2250. If the crankshaft is inadvertently turned beyond the E.P. mark, d o not turn it back but continue on round in a clockwise direction until the mark is exactly in-line with the pointer. To avoid serious damage to the valves and pistons once the cylinder head has been fitted, the crankshaft must not be rotated until the valves have been timed. continued

FIT CYLINDER HEAD AND ROCKER SHAFT

ASSEMBLY

Petrol engine

1. Temporarily fit the timing cover with pointer and crankshaft pulley.

2. Turn the crankshaft clockwise, in the normal running direction, t o bring numbers one and four pistons to T.D.C. If the crankshaft is inadvertently turned beyond T.D.C. do not turn it back, but continue on round until the T.D.C. mark on the pulley coincides with the pointer on the timing cover. D o not allow the crankshaft t o be moved again until the valves are timed.

ST613M

I l l

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2.25 LITRE PETROL AND DIESEL ENGINE 1121 i

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Petrol and Diesel engines

4. Clean the cylinder head and cylinder block mating faces. Position a ncw cylinder head gasket on the cylinder block with the word 'Diesel' or 'Petrol' uppermost.

5. Lower the cylinder head onto the cylinder block using two long bolts to facilitate accurate positioning of t h e head.

6. Fit the cylinder head retaining bolts except those also used to secure the rocker shaft and leave finger-tight .

7. Insert the push rods ensuring that the ball end locates properly in the spherical seat in the tappet.

8. Whilst holding the rocker shaft assembly together, lower it into position making sure that the hollow dowels locate properly in the cylinder head. Also ensure that the rocker adjusting screw ball end

. locate i n the push rods.

9. Fit the rocker shaft large retaining bolts and leave finger-tight.

VALVE TIMING

Petrol engines

1. Check that numbcrs one and four pistons are still at

T.D.C. and without disturbing thc crankshaft, remove the pulley and timing cover.

2. One of the keyways in t h e camshaft sprocket is stamped with the letter 'P' and this must locate on the camshaft key.

3. Fit the camshaft chain wheel, as above, and rotate the camshaft in a clockwise direction until the tooth also marked with a letter 'P' is in line with the top stud hole as illustrated.

ST8

10. Tighten the cylindcr head rctaining bolts, evenly, to the correct torque figure in the sequence illustrated below.

11. Fit and tighten t h e rocker shaft, small bolts to the specified torque.

13. Do not allow the crankshail to be turned, until the valves are timed.

4. Fit the crankshaft chain whccl with the large shoulder towards the cylinder block.

5 . Without moving either chain wheel, fit t h c timing chain, keeping it taut on the drive side. If it is not possible to obtain a taut fit on the drive side of the chain with the chain wheel in the set position, withdraw the camshaft chain wheel without disturbing the camshaft, and rcfit the chain wheel on one of t h e alternative keyways. This procedure may be repeated until a taught chain is obtained on the drive-side with the camshaft and crankshaft in their previously set positions.

6. Secure the camshaft sprocket to the camshaft with a new special micro encapsulated treated bolt and tighten to t h e correct torque figure.

NOTE: Early engines use an ordinary bolt and tab was her.

7. Fit and adjust the timing chain damper

S O that there is a maximum clearance of 0 2 5 mm

(0.010 in) between the timing chain and damper.

Tighten the retaining bolts and secure with new lock tabs. continucd

1121

2.25 LITRE PETROL AND DIESEL ENGINE

11. Manufacture a suitable pointer, and attach one end to the top bolt hole i n the cylinder block and the pointer close to the camshaft chain wheel, 21s il Ius t ra ted .

12. Turn the camshaft until the valve is fully open

;IS indicated by maximum reading on the dial gauge.

13. Because the top of the cam is ‘flat’ t h e cnmshaft can be turned

;i furthcr four degrees without movement of the dial gauge needle. Since an error of four degrees is not acceptable, the exact centre of the four degree period must be established.

;IS follows.

14. Without moving the camshaft rub white chalk on the face of the chain wheel adjacent to t h e pointer.

Zero the dial gauge and carefully turn the camshaft clockwise until the needle indicates 0,25 mni

(0.010 in) which represents a point down the left- hand side of the cam lobe. Make a thin pencil mark, on the chalk, in line with the pointcr. Diesel engines

8. Maximum engine performance and efficiency depends upon the care and accuracy excerciscd during the following instructions.

9. Check that the E.P. mark on the flywheel is still cxactly aligned with the pointer on thc flywheel lious i n g .

10. Thc valve timing is based upon the exhaust valve peak of number one cylinder. To determine the point at which the valve is fully open mount a dial test indicator, as illustrated, with the bracket attached to the number one exhaust valve rocker and the stylus resting, in a loaded condition o n a cylinder head bolt head.

15. Turn the camshaft anti-clockwise and watch the needle move back to zero. Then continue turning until the necdlc indicntcs 0.25 inn1

(0.010 in) which represents a point down the right-hand sick of the cam and n:::ke ::nother ;xark in !inc wi!h !!le pointer.

2.25 LITRE PETROL AND DIESEL ENGINE

16. Using a rule, determine the exact mid-point between the two marks and make a third mark.

17. Remove the dial indicator, and turn the camshaft until the middle mark lines up with the pointer.

The number one cylinder exhaust tappet roller should now be resting in the centre of the four degree flat period of the cam and the camshaft and crankshaft are in their correct relationship.

FIT TIMING CHAIN TENSIONER

I . Assemble the timing chain tensioner in accordance with t h e illustration in “Dismantling”.

2. Compress the assembly against the spring and fit to the engine whilst engaging thc ratchet pivot bolt in the cylinder block.

3 . Ensure that the piston housing locates on the dowels and single stud and the cylinder spigot fits into the milled slot in the cylinder block.

3 . Allow the jockey wheel to take up the slack in the chain. Tighten the retaining n u t and two bolts to secure t h e assembly. Do not rotate enginc, see

‘tappet adjustment’.

. ...

18. Fit the crankshaft chain whee! with the large shoulder towards the cylinder block.

19. Without moving the camshaft and crankshaft fit the timing chain keeping i t taut on the drive side.

Should i t be impossible to obtain a taut fit, remove the chain wheel and position i t in one of the five remaining keyways until the best position is obtained. It is preferable to choose a keyway which gives

;I slightly tight chain on the drive side rather than a slack one.

20. Secure the camshaft chain wheel to the camshaft with a new, special, micro encapsulated treated bolt and tighten to t h e correct torque figure -

21. Fit and adjust the timing chain damper so that there is a maximum clearance of 0 3

(0.010 i n ) between the timing chain and damper.

Tighten the two bolts and secure with new lock tabs.

11211

2.25 LITRE PETROL AND DIESEL ENGINE

ADJUST TAPPET CLEARANCES

Petrol and diesel engines

1. If t h e crankshaft is rotated with excessive valve clearances, it is possible that the push rods may become dislodged from the tappet seating and fracture the tappet slide. To prevent damage, eliminate all clearance from any loose rockers bcfore turning the crankshaft to adjust the clearances.

2. Turn t h e engine over until number eight valve

(counting from front of engine) is fully open.

3. Using a 0,25 mm (0.010 in) feeler gauge check the clearance between the valve tip and rocker pad of number one valve.

4. Adjust the clearance by slackening the locknut and turning the tappet adjusting screw clockwise to reduce clcarance and anti-clockwise to increase clearance. Recheck the clearance after tightening the lock nut.

FIT TIMING COVER AND WATER PUMP

1. Using a new joint washcr assemble the water pump to the front cover and loosely tighten the three retaining bolts.

2. Attach a new joint washer and water gallery joint to the timing cover and secure the cover together with the timing pointer (petrol engines only) and alternator link to the cylinder block with the fourteen bolts. Evenly tighten to the correct torque figure, including the water pump bolts.

5 . Continue to check and adjust the remaining tappets in the following sequence:

Set No. 3 tappet with No. 6 valve fully open.

Set N o . 5 tappet with No. 4 valve fully open.

Set No. 2 tappet with No. 7 valve fully open.

Set No. 8 tappet with No. 1 valve fully open.

Set N o . 6 tappet with No. 3 valve fully open.

Set No. 4 tappet with No. 5 valve fully open.

Set N o . 7 tappet with No. 2 valve fully open.

ST1269M

3. Fit the crankshaft pulley and secure with the special washer and bolt. Tighten to the correct torque figure.

ST1089M

2.25 LITRE PETROL AND DIESEL ENGINE

4. Fit the thermostat into its housing and using new joint washers secure the assembly, together with the elbow, to the cylinder head. Tightcn the three bolts to the correct torque. Connect the thermostat elbow to the water pump with a new hose and secure with hose clips.

FITTHESKEW GEAR

Petrol engine

1. Turn the crankshaft to bring number one piston to

T.D.C. with number four cylinder valves on thc

'rock'. Check that the timing gear pointcr coincides with the mark on t h e crankshaft pulley.

2. Lubricate and insert the skew gear assembly into mesh with the camshaft gear. Due to the helex angle o f the teeth the gear will turn anti-clockwise as it slides into mesh. The broad master spline must be at 20" to t h e centre line when correctly seated, as illustrated, but i t may take scvcral attempts to achieve this.

ST 882M

3 . The skew gear assembly is located in its final position by a special screw. Without this screw the gear will go deeper into mesh resulting in an incorrect anglc when t h e assembly is lifted up to locate the screw. The angle must therefore be checked again after the screw is fitted. Align the location hole in t h e bush and fit a new location screw i n t o the cylinder block and re-check the angle.

4. Fit the distributor drive coupling, and ensure that it locates properly in the off-set slot of the skew gear.

5. Using a new joint washer, fit t h e side covcr.

ST748M

2.25 LITRE PETROL AND DIESEL ENGINE

Diesel engine

6. Turn the crankshaft in the direction of rotation until both valves of number one cylinder are closed and the piston is ascending the bore on the compression stroke.

7. Continue to turn the crankshaft until the timing pointer aligns with the 13" mark on the flywheel, that is 13" BTDC. This must be done carefully. If the flywheel in inadvertently turned too far and the timing mark goes past the pointer do not turn the flywheel back but repeat the operation.

8. Ensure that a correct line of vision is taken when lining up t h e timing marks. An incorrect line of vision can result in the timing being 1" to 2" out.

10. The skew gear assembly is located in its final position by a special screw. Without this screw the gear will go deeper into mesh rcsulting in a n incorrect angle when the assembly is lifted up to locate the screw. The angle must therefore be checked again after the screw is fitted.

11. Align the location hole i n the bush and f i t a new location screw into the cylinder block and re-chcck the angle.

12. Fit D . P . A . p u m p drive shaft long-splined-end leading and locate the master spline in the corresponding spline i n the skew gear.

.,..

9. Lubricate and insert the skew gear assembly into mcsh with the camshaft gear. Due to the helex angle of the teeth the gear will turn anti-clockwise as it slides into mesh. The broad niaster spline must be at 20" to the centre line when correctly seated, as illusti-ated, but it may take several attempts to achieve this.

Petrol and Diesel engines

13, Using a new joint washer fit the oil filter housing, ensuring that the retaining bolts pass through the two small round holes i n the joint washer.

Tighten the iwii rciaining bolts evenly to :tic corrcc: torque.

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ST750M

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-. FIT ICNITIOPI DISTRIBUTOR

I . Fit the distributor adaptor plate using a new joint washer and evenly tighten the thrcc retaining bolts to the correct torque figure.

2.25 LITRE PETROL AND DIESEL ENGINE

1121

6. Fit the correct spark plugs and washers and tighten to the specified torque figure.

7 . Fit the distributor cap and connect t h e H.T, leads to the spark plugs in t h c sequcnce illustrated.

ST 877M

2. Chcck that the distributor drive coupling, locates properly in thc off-sct slot of the skew gear.

3. Inserl t h c distributor and “0” so that thc vacuum unit faccs towards t h e rear of the engine.

Remove the cap and oscillate the rotor arm until the distributor drive shaft locates into the drive coupling slot thus enabling the distributor to be pushed fully home. The metal tip of the rotor arm should be in line with thc electrode in the distributor cap that supplies clcctrical current to number one spark plug.

4. Temporarily tighten the distributor clamp bolt pending final ignition timing adjustment when the cngine is fitted to the vehicle.

5. Secure the clamp to the adaptor plntc with the single bolt. w r

F UEL I N JEC T I O N P UMP

Using timing gauge 605863

1. Using a new joint washer fit the camshaft front side cover with t h e timing pointer. Tighlcn the retaining bolts evenly to the correct torque.

2. Earlier engines with the side oil filter, cmploy a baffle plate, with two joint washcrs interposed between the side filter plate and the cylinder block. continued

1121 2.25 LITRE PETROL AND DIESEL ENGINE

3. Insert the timing gauge, 605863, into the driving gear, then twist gauge in a clockwise direction to take up backlash and any wear in the gears.

4. Hold in this position, then, if necessary, slacken off bolts retaining the timing pointer on the side of the cylinder block. Adjust pointer so that it coincides with the line on the timing gauge, as illustratcd, then retighten the bolts and remove the timing gauge.

Using timing gauge MS 67B

9. Check that the drive shaft is correctly located with the longer splined-end in thc skew gear.

10. Assemble the scribing arm of the timing gauge to the gaugc body.

11. Set gauge by loosening knurled screws and sliding bracket around until chamfcred edge aligns with the required angle of 22", tighten knurled screw in this position.

5 . Rotate the driving gear on the distributor pump so that the master spline lines up with the mastcr spline on the engine driving gear.

6. Check that the pump drive shaft is correctly located with the longer splines in thc skcw gear.

7. Fit the distributor pump to the engine engaging the master splines on the pump and the drive shaft. Do not tighten the fixings at this stage.

8. Align the vertical mark o n the pump flange with t h e pump timing pointer, then tighten the pump fixings.

ST759M

12. Insert the gauge into the vacant injection pump position and engage the gauge gear into injection pump drive splines.

ST760M

ST757M

2.25 LITRE PETROL AND DIESEL ENGINE 1121

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13. Release centre shaft retaining screw and slide the gauge body along centre shaft until body engages injection. pump drive gear hub. Lock shaft retaining screw.

14. Apply gentle clockwise pressure to take up backlash or wear in gears, retain in this position.

15. Slacken off timing pointer bolts. Adjust timing pointer so that it aligns with scribing arm on the gauge.

16. Tighten timing pointer bolts and remove the gauge.

17. Rotate driving gear on distributor pump so that master spline lines up with master spline on driving gear.

18. Fit pump to engine, ensuring that the timing mark on the pump flange coincides with the timing pointer.

19. Tighten the injection pump retaining nuts.

20. If the injectors have already been fitted, during cylinder head assembly, fit the injector feed pipes to the injector pump to prevent the ingress of dirt into the system. See FUEL SYSTEM for correct fitting of injectors.

- Section 19

NOTE: When the distributor pump is timed as detailed above, that is, with the timing pointer on the engine altered to take up backlash and wear on the gears, it ensures that optimum distributor pump timing is achieved.

Should there be any fall-off of power during the life of the engine, retiming the distributor pump to take up gear wear could well make a significant improvement to engine performance, provided the engine is generally in good condition. continued

FIT OIL PUMP AND SUMP

1. Fit the longer splined end of thc drive shaft into the oil pump.

2. Fit the oil pump and drive shaft to the crankcase, whilst revolving the shaft as necessary to engage the splines of the skew gear.

3 . Using new lock washers, secure the pump to the crankcase tightening t h e bolts to t h e correct torque and bend over the lock tabs.

4. If necessary adjust t h e position of the strainer

S O that it is parallel to the sump baffle plate.

5 . Clean the sump and crankcase mating faces and fit a new joint washer. Secure the sump with the twenty-one bolts and spring washers and one nut.

Evenly tighten to the correct torque.

2.25 LITRE PETROL AND DIESEL ENGINE

FIT FUEL LIFT PUMP

If the fuel lift was separatcd from the side cover, fit the pump to the cover first using a new joint washcr and evenly tighten the retaining nuts.

Place a new cover plate joint washer in position and f i t the cover and pump assembly to the cylinder block.

Ensure that the pump actuating lever ridcs on top of the camshaft.

Secure t h e cover, evenly tightening the retaining bolts.

FIT ROCKER COVER

Clean the rocker cover and cylinder head faces and f i t the cover using a new joint washer. Evenly tighten the dome headed nuts to the correct torque. Do not ovcrtighten.

A . Petrol engine

B. Diesel engine

ST762M

S T 881 M

FIT HEATER PLUGS -

1. Clean and test the heater plugs as described in the maintenancc Section. Fit thc heater plugs and tighten to the corrcct torque according to the size of plug. D o not ovcr tighten.

2. Fit the leads, washcrs and nuts as illustrated.

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ST763M

-4

NOTE: The illustration shows a petrol engine fuel pump but the fitting procedure is the same for the Diesel engine pump.

ST127C!M

2.25 LITRE PETROL AND DIESEL ENGINE la

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FIT THE CLUTCH

1. Clean the flywheel face and place the centre plate with the side marked ‘Flywheel side’ towards the flywheel.

2 . Fit the clutch assembly locating i t over the three dowels and loosely secure with the six bolts.

3. Centralise the centre plate using special tool RO

605022 or a spare primary shaft and tighten the six bolts evenly to t h e correct torque figure. Smear the splines of the centre plate with Molybdenum disulphide grease, such as Rocol MTS 1000.

FIT INLET AND EXHAUST MANIFOLDS

Petrol engine

1. Using a new ‘hot spot’ joint washer asscmblc the inlet manifold to thc exhaust manifold.

2. Secure with the four nuts and evenly tighten to the correct torque, t h e n slacken off but retain the ‘nip’ of the four nuts.

ST764M

...

FIT CYLINDER HEAD OIL FEED

1 . Connect the oil feed pipe, for lubrication of the rocker shaft assembly, to the cylinder head.

2. Secure with the two banjo bolts and f o u r joint washers.

3 . Coat the face of the exhaust manifold with Rocol

4. anti-seize compound Foliac J 166 (paste) and the corresponding face of the cylinder head.

Fit t h e joint washcrs of inlet manifold with the raised rings towards the cylinder head.

5 . Fit and tighten the securing nuts and bolts to the correct torque including the two common bolts and clamps. Note the two outer bolts at both ends of the exhaust manifold have lock plates.

6. Finally tighten the f o u r ‘hot spot’ joint nuts cvcnly to correct torque.

7. Fit the heat shield.

ST767M

1121

2.25 LITRE PETROL AND DIESEL ENGINE

Diesel engine

7. Using a new gasket fit the manifolds and secure with the retaining nuts and clamps. Evenly tighten to the specified torque figure.

2. Assemble the alternator to the engine bracket with the two pivot bolts, distance piece and washers, leaving the bolts slack.

3 . Fit the adjustment link t o the timing cover and attach to alternator with the adjusting clamp bolt.

ST768M lil

FIT ALTERNATOR, PULLEY AND FAN BLADES

1. Fit the pulley, spacer and fan blade assembly 10 the water pump shaft.

4. Fit the drive belt and pivot the alternator away from the engine, but d o not apply pressure to the stator or slip-ring end bracket or damage may result. Tighten the clamp bolt and with thumb pressure, check the belt tension between the Can and altcrnator pulleys which should be 7 t o 9 mm

(Y4 t o ?4 in) at the mid-point.

5 . When the tension is correct fully tighten the clamp bolt and the pivot nuts and bolts.

2.25 LITRE PETROL AND DIESEL ENGINE 12

I . Clean the carburettcr and manifold mating faces.

2. Place a joint washer, over the studs to the manifold.

3. Fit the packing piece.

4. Fit a second joint washer.

5 . Fit the carburetter and secure with the four nuts and washers tightening evenly to thc correct torque.

1. Fit the pump attachment bracket to engine with two bolts.

2. Secure pump to bracket with pivot bolt and nuts leaving it slack.

3. Fit the tensioning clamp bolt and drive belt.

Tension the belt and tighten the clamp bolt.

4. Check that the belt can bc deflected 12 mm (E i n ) by thumb pressure, at t h e mid-point of its r u n (A).

5 . Tighten the pivot bolt and n u t and finally tighten the clamp bolt.

FIT THE STARTER MOTOR

1. Secure the starter motor to the flywheel housing noting that the petrol engine starter is held by two studs, nuts and washers. The startcr for the diesel engine is retained by one stud, one bolt and one nut and bolt. Tighten the fixings evenly to the correct torque.

2. In addition, the rear of the Diesel engine starter motor is secured by two bolts to a support bracket attached to thc cylinder block.

6. Turn the pump pulley so that t h e indicating marks on the pulley hub and pump body line up.

7. Remove the oil level plug and inject a rccommended S A E 15W-50 oil up to t h e level of the hole. Refit the plug. See Maintenance Section.

MISCELLANEOUS iTEit'iS

Fit any other parts, if removed, such as engine mounting brackets, lifting eyes and the dipstick. Also any other items of non-standard equipment peculiar to the vehicle concerned.

Make a careful inspection of the engine and check that all plugs are fitted and properly tightened.

112 1

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

REMOVE OVERHAUL AND REFIT

Special tools:

Drift inlet valve guides 274400

Drift exhaust valve guides 274401

Drift exhaust valve guide 600959

Drift inlet valve guide 601508

Seat cutters MS621 MS627

Insert replacer 530625

Before the cylinder head can be removed the following ancilliary items, common to petrol and diesel engines, need to be removed or disconnected for access and safety.

I . Disconnect the battery for safety.

2. Drain the cooling system.

3. Remove the bonnet.

3. Disconnect heater rail pipes and move aside.

5 . Disconnect top hose from thermostat housing.

6.. Disconnect hcater control cables.

7 . Release fan cowl from bracket attached to t h e r m os t a t ho usi n g

8. Disconnect lead from coolant temperature sensor.

9. Disconnect oil gallery pipe at rcar of engine.

10. Disconnect coolant by-pass hose.

1 1 . Disconnect the exhaust pipc from the manifold.

The following items concern the petrol engine only

I ? . Disconnect the air cleaner hose from the carburetter.

13. Disconnect brake vacuum hose from the

14. manifold.

Disconnect mixture control cable from carburetter.

15. Disconnect throttle cable.

16. Disconnect fuel shut-off valve lead from carburetter.

17. Disconnect vacuum ignition advance pipe.

18. Remove H.T. leads from spark plugs.

The following items concern only the diesel engine

19. Disconnect the fuel spill return union conncctcd to spill rail.

20. Disconnect injector supply pipes from the injectors.

21. Remove injectors complete with spill rail.

22. Disconnect air hose from manifold.

23. Disconnect the heater plug electrical connections.

Remove the cylinder head

The following instructions for removing and overhauling the cylinder head are common to petrol and diesel engines unless otherwise stated.

24. Remove the rocker cover and slacken the tappet screw lock nuts. Turn the adjusting screws to release them from the push rods.

25. Remove the rocker shaft retaining bolts, lift-off the rocker shaft assembly, invert it and secure i t to the rocker cover studs to prevent the assembly from falling apart.

26. Withdraw the push rods and retain them in numbered sequence.

27. Evenly slacken the remaining cylinder head retaining bolts and lift-off the cylinder head complete with manifolds. Remove and discard thc cylinder head gasket.

ST674M

28. Remove the eight bolts and three nuts and remove the inlet and exhaust manifolds complete with carburetter (petrol engine).

29. Remove three bolts and lift-off the thermostat housing, elbow and thermostat.

30. Removc spark plugs, (pctrol cnginc) tcmpcrature

31. sensor and engine lifting eyes.

Using valve spr-ing compressor 276102 or

;I suitable alternative, remove the valve and spring assemblies, keeping them identified w i t h their original locations for possible refitting. Discard the valve spring and valve guide oil seals. Remove carbon deposits from the valves and combustion chambers and dcgrcase all parts ready for examination. e-

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

34. To remove a hot plug, insert a thin soft metal drift through the injector shroud throat and tap the hot plug from the inside. Once removed a faulty hot plug cannot be restored and must be renewed.

35. I f the injector shroud is damaged, drift the shroud out towards the injector bore.

36. Thoroughly clean out the combustion chamber.

The hole in the side of the injector shroud is for manufacturing purposes only but at the same time can be used as a guide when refitting the shroud.

37. Smear a little oil on t h e shroud and insert into the cylinder head with the hole pointing towards the centre of t h e cylinder head, and drift into position.

. .

ST675M

34 38

ST677M

EXAMINATION OF COMPONENTS

Petrol engine

32. Examine t h e cylinder head for cracks and distortion. Burnt, pitted and pocketed seats must be repaired.

Diesel engine

33. Same as for petrol engine and in addition, worn or damaged exhaust seat inserts should be renewed, as described later.

38. Fit the hot plugs by tapping with a hidc-faced mallet, and locate with a new roll pin. If thc hot plugs are loose in the cylinder head they may be retained with a little grease.

39. When fitted, the hot plugs must be checked with ii dial test indicator to ensure that they do not protrude above the level of the cylinder head Cace more than 0,025 mm (0.001 in) and are not recessed below the level of the cylinder head face more than 0.05 mm (U.002 i n ) .

. .

, .

Hot plugs and injector shrouds

- renew

When carrying out normal top overhaul work on the cylinder head i t is not necessary to rcmove either the injector shrouds o r the hot plugs.

Small surface cracks in the hot plug, extending from the opening to approximately 8,O inn1 (,0.312 i n ) in length can be ignored. However i f any severe cracks appear on the face of the hot plug, before attempting to remove i t , closely inspect t h e cylinder head for signs of cracks, particularly between the inlet and exhaust valve seats.

Such cracking indicates that the engine has overheated, usually through lack o f coolant, and the cylinder head hhould be scrapped. ST678M

1121 2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

Petrol and diesel engines

40. Chcck the valve guides for wear by inserting a new valve in the appropriate guide 8 mm above the seat. If movement across the head exceeds

0,15 m m

41. Inspect the valves and discard any that are burnt, bent or distorted. Check the stems for wear by inserting in a new guide. If wear is excessivc, discard the valve. Valve faces that are pitted o r ridged but otherwise serviceable may be refaced.

42. Renew push rods that are bent or have worn or scored ball or socket ends.

Renew push rod tube seals (Diesel only)

43. Whilst this is rarely necessary the procedure is nevertheless as follows.

44. Drive out the old push rod tubes using a suitable drift.

NOTE: Later engines are fitted with tubes without seals.

See 2.5 litre Diesel engine for renewal.

45. Fit new sealing rings to new push rod tubes and smear with silicone MS4 grease.

46. Insert the new tubes, chamfered end first from t h e combustion chamber side. Align t h e flat on the push rod tube at right angles to an imaginary line between the centre of the push rod tube and centre of the hot plug.

47. Press the push rod tubes into position whilst maintaining the alignment. Also ensure that the chamfers on the tubes and in the cylinder head are fully engaged.

Renew valve guide

48. Support the cylinder head, combustion chamber uppermost on pieces of timber of sufficient thickness to allow clearance for the valve guides to be driven out.

49. Using special drift 274400 for inlet guides and

274401 for exhaust guidcs or suitable alternatives drive out the old guides from the combustion face side.

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NOTE: The illustration shows a petrol engine cylinder head.

,...

._:

;

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD 12

50. Turn the cylinder head over so the combustion chambers face downwards. Since the inlet and exhaust valve guides are dimensionally different it is important that the correct guides are fitted to the appropriate ports.

51. Lubricate new guides with engine oil and using special drift 600959 for the exhaust and 601508 for the irrlet valve guides or suitable alternatives, drive in the new guides until the shoulder is flush with the casting.

53. The special set of hand tools recommended for refacing include expandable pilots that fit tightly into new or worn guides to ensure that the valve seat is concentric with valve guide. The refacing tool has tungsten carbide cutters and can be used to cut a seat in a new exhaust seat insert.

54. Select the correct expandable collet for the valve guide concerned i.e.

8 3 m m for exhaust.

8 mm for inlet guides and

55. Loosely assemble the collet, expander and nuts.

Ensure that the chamfered end of the expander is towards the collet.

.,.

: .

I .

Reface cylinder head valve seats

52. Damaged or worn valve seats can be refaced provided they are not abnormally wide due to repeated refacing operations. See instruction 64.

ST594M

56. Insert the assembled pilot into the valve guide from the combustion face side of the cylinder head until the shoulder contacts thc valve guidc and the whole of the collet is inside the valve guide.

57. Expand the collet in the guide by turning the tommy bar clockwise whilst holding the knurled nut.

58. Select t h e appropriate angled cutter for the seats to be cut. continued

'. /

ST668M

U " A. Correctly seated valve

B. Undesirable condition

C. Method of rectification

(1211

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

NOTE: MS 621 is a 45" and 15" cutter and MS 627 is 30" only.

A - Petrol engine inlet valve seat 30"

W exhaust valve seat 45"

9"'

13 Diesel engine inlet valve seat 45"

'h" exhaust valve seat 45"

See illustrations following instruction 68.

59. Ensure that the cutter blades are correctly fitted to the cutter head with the angled end of the blade downwards facing the work, as illustrated. Check that the cutter blades are adjusted so that the middle

IJf the blade contacts the area of material to be cut. Use the key provided i n the hand set

MS 76.

62. Smear a small quantity of engineers' blue round the valve seat and revolve a properly ground valve against the seat. A continuous fine line should appear round the valve. If there is a gap of not more than 12 mm i t can be corrected by lapping.

63. Alternatively, insert a strip ofcellophanc between the valve and seat, hold the valve down by the stem and slowly pull out t h e cellophane. If there is a drag the seal is satisfactory in that spot. Repeat this in at least eight places. Lapping-in will correct a small open spot.

64. After several trueing-up o r lapping-in operations valve seats may have an excessive width which can be reduced by obtaining special correction cutters which narrow t h e seat by removing metal from the top and bottom of the scat. A 60" cutter is recommended for bottom narrowing and for top narrowing use a 15" cutter (MS 621) for a 30" valve seat and a 30" cutter for a 45" seat. The same mcthod of assembly and operation is used for- correction cutters as for refacing cutters. IJse very light pressure removing only the minimuni material necessary. Once the seats have been reduced carry out the normal refacing operation as previously described. cQ

Renew exhaust seat inserts (Diesel only)

65. Hold the cylinder head firmly in a vice, wear protective goggles and grind the old insert away until thin enough to be cracked and prised out.

Take care not to damage the insert pocket.

66. Remove any burrs and swarf from the pocket.

Failure to do this could cause the new insert to crack when being fitted.

67. Assemble the new insert to the replacer tool number 530625 so that the chamfered edge of the insert is l a d i n g . Using it suitable bolt and n u t draw the insert into the cylinder head pocket.

Cut ii new 45" seat using cutter MS 621. 60. Fit the wrench to the cutter head and turn clockwise using only very light pressure. Continue cutting to approximately the centre of the existing seat.

61. T o check. the effectiveness of [ne cutting operation use engineers' blue or a feeler gauge made from cellophane.

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

112 I

; c .

Reface valve faces

68. Valves that are satisfactory for further service can be rcfaced. This operation should be carried out using a valve grinding machine. Only the minimum of material should bc rcmoved from the valve face to avoid thinning of the valve edge. The valve is refaced correctly when all pits are removed and the face concentric with the stem.

Valve face angles:

A . Petrol engine

Inlet valve face

- -

Exhaust valve face

B. Diesel engine

Inlet valve face -445"- %"

Exhaust valve face 45" -

'+ F

A h ssE9?LJE

Lap-in valves

69. To ensure a gas tight seal between the valve facc and valve scat it is necessary to lap-in the appropriate valve to its seat. It is essential to keep the valve identified with its seat once the lapping- in operation has been completed. Rcmember that the inlet and exhaust valves in thc petrol engine have different face angles.

70. Unless the faces to be lapped are in poor condition it should only be necessary to use fine valve lapping paste. Smear a small quantity of paste on the valve face and lubricate the valve stem with engine oil.

71. Insert the valve in the appropriate guide and using a suction type valve lapping tool employ a light reciprocating action while occasionally lifting the valve off its seat and turning it so that the valve returns to a diffcrent position on t h e seat.

72. Continue the operation until a continuous matt grey band round thc valve face is obtained. To check that the lapping operation is successfull, wipe off the valve paste from the valve and scat and make a serics of pencil lines across the valve face. Inset the valve into the guide and while pressing the valve onto the seat revolve the valve a quarter turn a few times. If all the pencil lincs are cut through no further lapping is required.

73. Wash all traces of grinding paste from the valves and cylinder head seats. con tin lied

ST690M v

ST670M

Assemble valves to cylinder head

74. Insert the inlet valves into the guides and fit new oii seais with the piain exterior and circuiar spring. Ensure that t h e seal locates in the groove in t h e valve guide.

75. Insert the exhaust valves and fit the oil seals with the ridged exterior and n o spring. continued

1121 2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

76. Fit the double valve spring and retainer assembly to each valve in turn and using valve spring compressor, 18G106A with adaptor 18G106A/10 secure the assembly with the split collcts.

7 5

ST669M

~ 7

ST6

79 Examine the rocker shaft for wear and discard i f the bearing surfacc is worn more than 0,025 mm

(0.001 i n ) .

Inspect thc rockers and discard if the pads are worn. It is not permissible to grind pads in an attempt to reclaim the rockers.

Renew bushes if the clearance between shaft and

6 bush is in excess of 0,101 to 0,127 mm (0.004 to

0.005 in).

Press in replacements ensuring that thc pre-drilled oil holes coincide with the holcs in the rockcrs.

Illustration A . Cross section of petrol engine rocker.

Illustration B . Cross section of diesel engine rocker.

OVERHAUL ROCKER SHAFT ASSEMBLY

Most of thc rocker shaft assembly components are not interchangeable between the petrol and diesel engines although the assembly method is the same.

Dismantle and inspection

77. Remove the locating screw and washer from the number two rocker bracket and withdraw all the components from the rocker shaft. Note that on the petrol engine the locating screw also retains a splash plate.

78. Remove the locknuts and adjustment screws from the rockers.

ST684M

81. Using a reamer finish the bushes to 13,4 mm

0,02 m m (0.530 in

0.001 in) and clear swarf from the oil holes.

82. Examine the ball-end of t h e adjusting screws and discard any that are worn. Regrinding is not permissible. Check the threads for damage and that t h e oil relief drilling is clear.

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

1121

,,:

>::.

:.':;,,.+

;:'.?a? _.-.

_ I

Assemble rocker shaft assembly

83. Check that the oil-ways in the rocker shaft are clear and fit number two rocker shaft bracket to the shaft and retain with the locating screw and washer. Note that the locating screw on petrol engines also secures the splash plate.

84. Using new spaccrs and springs, assemble the rockers and brackets to the shaft as illustrated, ensuring that the rockers move freely on the shaft.

Note that the Diesel engine assembly has double spacers each side of the centre pedestal.

Illustration C. Petrol engine assembly.

Illustration D. Diesel engine assembly

85. Fit the tappet adjustment screws and lock nuts to the rlxkers.

86. Invert the rocker assembly and locate it on the rocker cover to prevent i t falling apart. continued

ST688M f

814

1121 2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

Fit the cylinder head

87. Cleaii the cylinder head and cylinder block mating faces and fit a new gasket, dry, without grease or sealing compound. The gasket will have either

'DIESEL' or 'PETROL' stamped in the position illustrated and the gasket must be fitted with these uppermost.

88. Place the cylinder head in position and engage all the cylinder head bolts and washers except those used to secure the rocker assembly. Use new bolts and ensure that the correct bolts for the petrol and diesel engine are fitted. They are not interchangeable.

92. Adjust the tappet clearances for petrol and diesel engines, inlet and exhaust to 0,25 mm (0.010 in) as follows: Using a feeler gauge adjust the clearance by slackening the locknut and turning the tappet adjusting scrcw clockwise to reduce clearance and anti-clockwise to increase clearance.

Set N o . 1 tappet with No. 8 valve fully open.

Set No. 3 tappet with No. 6 valve fully open.

Set No. 5 tappet with N o . 4 valve fully open.

Set No. 2 tappet with No. 7 valve fully open.

Set No. 8 tappet with N o . 1 valve fully open.

Set N o . 6 tappet with No. 3 valve fully open.

Set No. 4 tappet with N o . 5 valve fully open.

Set N o . 7 tappet with No. 2 valve fully open.

93. Recheck the clearances with the locknuts tightened and adjust as necessary.

ST687M ' '

89. Insert the push rods into position ensuring that the ball-ends fit correctly into the spherical seats i n the tappet slides.

90. Fit the rocker shaft assembly ensuring that the hole in the front and rear rocker bracket locates properly in the corresponding dowel in the cylinder head. Also, make sure that thc ball-end of all the rockers f i t into the spherical seats of the push rods. Evenly tighten the rocker shaft retaining bolts to the correct torque.

91. Tighten the cylindcr head and rocker shaft securing nuts and bolts strictly in the sequence illustrated to avoid distortion of the cylinder head.

Tighten to the torque figures given in the data section. The arrow points to the front of the engine

2.25 LITRE PETROL AND DIESEL CYLINDER HEAD

94. Using a new gasket f i t the rocker cover and secure with the rubbers, cups and dome nuts. Tighten to the correct torque figure. Do not over-tighten.

A . Petrol. B. Diesel

:,.

ST671 M

95. Fit the inlet and exhaust manifolds complete with carburetter (petrol engine). Sec Engine overhaul.

96. Fit the air intake and exhaust manifolds (diesel enginc). See Engine overhaul.

97. Fit the spark plugs (petrol engine).

98. Fit the injectors- see Diesel fuel system.

99. Fit thc engine lifting cycs.

100. Fit the water temperature sensor.

Fit the thermostat housing assembly

101. IJsing a new joint washcr secure the thermostat housing to the by-pass housing.

102. Fit the two hose adaptors.

103. Inscrt the thcrmostat into its housing.

104. Place a ncw joint washer on the cy!inder head.

105. Using ii n e w joint washer f i t the thermostat cover and cowl mounting bracket.

106. Using the. three bolts sccurc the complete assembly to the cylindcr head. Note that one bolt is shorter and is fitted in-board.

ST672M

107. Refit or reconnect the items disturbed for access to the cylinder head.

108. Refill the cooling system when engine is refitted to vehicle.

2.5 LITRE PETROL ENGINE

2.5 LITRE PETROL ENGINE

SUPPLEMENT T O THE

2.25

LITRE PETROL

ENGINE OVERHAUL PROCEDURES

This S u p p l e m e n t should b e used in conjunction with t h e 2.25 litre petrol engine overhaul procedures.

Details of the differences between t h e 2.25 and 2.5 litre engines are listed below. Some of the new features were, however, introduced o n later 2.25 pctrol engines.

Capacity increased to 2495 cc by lengthening the piston stroke from 89 mm to 97 mm.

Inserts fitted to exhaust valve seats in cylinder head.

Crankshaft and main bearings same as the 2.5 litre

Diesel engine.

New timing chain tensioner assembly

Modified oil pump with gear having only ten teeth.

Bush deleted from idler gear and ball ommitted from the pressure relief valve.

Oii squirt hole in connecting rods deleted.

New pistons with controlled expansion skirts.

The ‘0’ cylinder block deleted. Sealing now achieved by a bead of sealant on the flywheel housing mating face with the cylinder block.

Camshaft same as 2.5 litre Diesel engine.

Camshaft sprocket similar to 2.25 litre petrol engine, but with a single keyway positioned to alter the exhaust value peak from 109” to 104”.

Sump joint washer deleted and a liquid sealant, RTV

Hylosill 102, now used.

The Lucas 45 D4 sliding contact distributor now used.

2.5 LITRE PETROL ENGINE

112

_..._.

,..

...-,..

:i::

-.,

REMOVE AND OVERHAUL OIL PUMP

1. Remove the sump.

2. Bend back the lock washers and remove the two bolts securing the oil pump to the crankcase.

Withdraw the oil pump complete with strainer and oil pump drive shaft.

Dismantle oil pump

3. Bend back the lock washer and release the nut securing the strainer to the oil pump body and remove the strainer and sealing ring.

4. Remove four bolts and washers and lift off the oil pump cover and lift out t h e driven and idler gears.

(a) driven gear

(b) idlcr gear

5 . Remove the oil pressure relief valve plug and sealing washer. Withdraw the relief valve spring and plunger.

Overhaul the oil pump

6. Examine the gears for wear, scores and pits. If the gears appear serviceable check for end-float as follows:

7. Clean the pump body and assemble t h e gears.

Place a straight edge across the pump body face, as illustrated, and using a feeler gaugc, measure the clearance between the body and gears and the backlash between the gcars. The correct clearances are given in Data.

STlG35M

ST1636M

8. Gears must be renewed in pairs. A worn, but serviceable gear, must not be matched with a new one.

9. If necessary renew idler gear spindle by drilling-out the peened over end of the spindle so that the spindle can be withdrawn from the pump body. To ensure squareness when fitting the new spindle, assembie it inio the pump body with the two gears.

Fit the cover and secure with the four bolts.

Support the pump body and peen over the end of the new spindle. Remove the cover and gears and check security of the spindle.

)121

2.5 LITRE PETROL ENGINE

Assemble the oil pump

10. Fit the idler gear to the spindle.

11. Fit the driven gear with plain part of the bore uppermost. See illustration after instruction 9.

5. Remove the camshaft sprocket retaining bolt and washer.

ST1637M

12. Smear thc joint face of the body with jointing compound and fit the cover over the dowels and secure witli the lour bolts and spring washers.

13. Hold relief valve bore vertically and insert the plunger with the solid end first. Fit the spring, sealing washer and plug.

14. Fit the oil strainer sealing ring to the pump body followcd by the lock washer and strainer. Tighten the strainer retaining nut so that when fitted the strainer is positioned parallel to the sump baffle plate. Secure the nut with the lock washer tab.

ST1665M

6. Withdraw the camshaft sprocket together with the timing chain and crankshaft sprocket. If necessary use special tool 507231.

REMOVE AND OVERHAUL THE TIMING CHAIN

SPROCKETS AND TENSIONER

1. Remove the bolts and withdraw the timing cover.

2. Before removing the timing chain tensioner check dimension 'A', which with a new chain and sprockets should be 14,22 mm (0.5 in) approximately. This will give an indication of chain wear. The dimension for a fully worn chain is 27 mm

(1.06 in).

3. Remove the three bolts and whilst holding the pad inwards, t o prevent it falling apart, remove thc tensioner asscmbly.

4. Remove timing chain damper.

7. Examine the sprockets and discard if the teeth are worn.

8. Dismantle the tensioner assembly and discard if any of the parts are worn.

9. Examine the tensioner body and check that the oi! inlet hole is clcar.

10. Examine the slipper and check that the oil outlet hole is clear.

11. Check that t h e oil inlet and exit oil hole in the tensioner mounting plate is clear.

2.5 LITRE PETROL ENGINE

ST7657M

16. To prevent the tensioner releasing, insert a spaccr approximately 2.3 mm thick between the tensioner body and back of the slipper prior to fitting to engine.

,:.

....- .

12. Assemble the tensioner body to the mounting plate with the two socket headed screws, spring washers and nuts.

13. Insert the spring into the slipper bore.

14. Fit the ratchet over the spring and against spring pressure, insert the ratchet into the slipper bore so that the groove in the ratchet locates over the small dowel inside t h e slipper bore. Push and turn the ratchet clockwise until it locks in the bore.

15. Insert the slipper assembly into the tensioner b o d y ensuring that the small flat on the slipper shaft faces the mounting plate.

ST 1 662M

112)

2.5 LITRE PETROL ENGINE

VALVE TIMING

1. Check that numbers one and four pistons are still at

T.D.C. and without disturbing the crankshaft, remove the pulley and timing cover.

2. Fit the camshaft sprocket temporally and rotate the camshaft in a clockwise direction until the line on the tooth, also marked with a letter ‘P’ is in line with the top stud hole on the cylinder block as illustrated.

6 . Fit and adjust the timing chain damper so that there is a maximum clearance of 0,25 m m

(0.010 in) between the timing chain and damper.

Tighten thc retaining bolts and secure with new lock tabs.

I I

3. Remove the camshaft sprocket.

4. Encircle the camshaft and crankshaft sprockets with the timing chain and keeping it taut on the drive side and with the large shoulder of the crankshaft sprocket towards t h e cylindcr block, fit the sprockets and chain assembly to the engine.

5. Secure the camshaft sprocket to the camshaft with a new special micro encapsulated treated bolt and tighten to the correct torque figure.

FIT TIMING CHAIN TENSIONER

1. Fit t h e timing chain tensioner and mounting platc assembly to t h e cylinder block locating i t ovcr the two dowels.

2. Secure the assembly with the three bolts and evenly tighten.

3. Remove the spacer and to release the ratchet, to tension the chain, prcss the pad at point ‘A’.

,, . :

...._

.:: _..

RENEW EXHAUST VALVE SEAT INSERTS

1. Hold the cylinder head firmly in a vice, wear protective goggles and grind the old insert away until thin enough to be cracked and prised out.

Take care not to damage the insert pocket.

Remove any burrs and swarf from the pocket.

Failure to d o this could cause the new insert to crack when being fitted.

NOTE: Since no special tool is available for fitting a new insert, it is recommended that this work is entrusted to a cylinder head overhaul specialist.

FITTING PISTONS AND CONNECTING RODS

The delection of the oil spray hole in the connecting rod precludes the necessity of fitting this towards the camshaft side of the engine. See page 18 instruction 5.

. - .

2.5 LITRE PETROL ENGINE

Fit rear main oil seal and flywheel housing

2. Check that the crankshaft oil seal journal is undamaged and clean. Make sure the scal housing is clean and dry and free from burrs. Do not touch the seal lip and ensurc that thc outside diameter is clean and dry.

3 . The P.T.F.E seal Part N o ETC 5369 which should be used is supplied with a former to maintain the correct shape and must not be removed until the seal is to be fitted.

4. Using special seal rcplacer 18G 134-1 1 and with the lip side leading drive-in the seal as far as the tool allows. If the tool is not available fit the seal to the bottom of t h e housing to ensure squarcness.

.... ..

REMOVE AND REFIT FLYWHEEL HOUSING AND

REAR MAlN OIL SEAL

1. Remove the eight bolts securing t h e flywheel housing to the cylinder block and remove the housing and rcar main bcaring oil seal.

ST1 842M

ST1 699M

2.5 LITRE PETROL ENGINE

5 . Apply a bead of Hylogrip 2000 sealant to the rear face of t h e flywheel housing to the dimensions and configuration as illustrated below. The illustration has been produced full size so that a template may be made to facilitate the application of the sealant.

The bead should be 5 3 mm wide and 0,25 mm thick.

6. Examine the seal guide number 18G 1344 and repair any damage that could destroy the seal lip.

7. Lubricate the outside diameter of the seal guide and the scal journal with concentrated 'Oildag' in a

25% solution with clean engine oil.

8. Place the seal guide on the crankshaft flange and, using the two dowels protruding from the cylinder block rear face as a guide to ensure initial squareness, fit the flywheel housing and remove the seal guide. Secure t h e flywheel housing evenly tightening the retaining bolts.

FITTING SUMP

1. Clean t h e sump and cylinder block mating faces.

2. Apply a bead of RTV HYLOSILL 102 black approximately 7 m m wide to the cylinder block or sump mating face.

3. Fit the sump within 30 minutes of applying sealant and secure with the bolts and tighten evenly to the correct torque.

NOTE: RTV Liquid Sealant is available under part number RTC 3254 from Land Rover Parts and

Equipment Ltd.

2.5 LITRE PETROL ENGINE

-4

5. The gear should revolvc freely in the bush with a clearance of 0,051 to 0,203 mm (0,001 to 0,007 in) between thrust washer and bush.

SKEW GEAR

I . To renew t h e bush, hold thc gear firmly i n a vice without damaging the teeth. If possibie insert a scrap drive shaft in the gear internal splines and grip the shaft.

2. Turn the locknut clockwisc (left-hand thread) to remove and withdraw the thrust washer and bush.

3. Fit a new bush removing any burrs before hand and ensure that the location hole is towards t h e lower end of the gear.

4. Fit a new thrust washer, if the original is worn or scored. Apply Loctite 601 to the thread and f i t the locknut turning anti-clockwise and tighten to 27 -

34 Nm (20 - 25 Ibf.tt).

1121

2.5 LITRE DIESEL ENGINE

ST1922M

2.5 LITRE DIESEL ENGINE

52 p7

*.: .....

2.50 LITRE DIESEL ENGINE

DISMANTLE AND OVERHAUL

Special tools:

274400

274401 - Drift exhaust valve guides

600959 -Drift exhaust valve guide

601508

MS621 - Seal cutter

530625

R0605022

Insert replacer

- tool

270304

18G 1344 -Seal guide

- rear main bearing

18G 134-11 -Seal replacer rear main oil seal

530102A -

18G 1457/1- Dist. pump remover

18G 1464/2/6

18G 1456 -Crankshaft oil seal replacer

18G 1482 - Camshaft oil seal replacer

18G 1458 -

MS47

18G705-1A -

LST107 -

REMOVE ANCILLIARY EQUIPMENT

Remove the engine from the vehicle. Clean the exterior and in the interests of safety and efficient working, secure the engine to a recognised engine stand.

Before commencing, make a careful note of t h e position of brackets, clips, harnesses, pipes, hoses, filters and other miscellaneous items to facilitate reassembly .

Removal of the following components is a reversal of the fitting procedure described in engine assembly.

1. Remove the alternator and mounting brackets.

2. Remove t h e power steering pump and bracket.

3. Rcmove the fan and pulley.

4. Remove the inlet and exhaust manifolds.

5. Disconnect and remove the fuel supply pipes from the injectors and D.P.S. pump and cover the ports.

6. Disconnect coolant by-pass hose from the water pump, release the seven bolts and remove t h e water pump.

7. Drain the sump and remove the dipstick.

8. Remove the starter motor.

9. Restrain the flywheel, remove the crankshaft pulley bolt and withdraw the pulley.

10. Evenly slacken and remove the clutch retaining bolts and withdraw the clutch assembly and centre plate.

11. Remove the two bolts and remove the oil filter assembly complete from the cylinder block.

Unscrew t h e filter element and discard.

12. Remove the six bolts and withdraw the rear side plate complete with fuel pump.

REMOVE AND OVERHAUL CYLINDER HEAD

Remove the cylinder head

1. Remove injectors complete with spill rail.

2. Disconnect the heater plug electrical connections.

3 . Remove the engine lifting brackets.

4. Disconnect oil gallery pipe at rear of engine.

5. Remove three bolts and lift-off the thermostat housing, elbow and thermostat.

6. Remove the rocker cover and slacken the tappet screw lock nuts. Turn the adjusting screws to release them from t h e push rods.

7. Remove the rocker shaft retaining bolts, lift-off the rocker shaft assembly, invert it and secure it to the rocker cover studs to prevent the assembly from falling apart, see instruction 25, page 34 2.25 litre

Petrol and Diesel engine.

8. Withdraw the push rods and retain them in numbered sequence.

9. Evenly slacken the remaining cylinder head retaining bolts and lift-off t h e cylinder head.

10. Remove the engine lifting eyes.

11. Using valve spring compressor 276102 or a suitable alternative, remove the valve and spring assemblies keeping them identified with their original locations for possible refitting.

12. Discard the valve spring and valve guide oil seals.

Remove carbon deposits from the valves and combustion chambers and degrease all parts ready for examination.

Examine components

13. Examine the cylinder head for cracks and distortion.

14. Burnt, pitted and pocketed seats must be repaired.

15. In addition, worn or damaged valve seats should be renewed, as described later.

Hot plugs and injector shrouds -examine and renew

When carrying out normal top overhaul work on the cylinder head i t is not necessary to remove either the injector shrouds or the hot plugs.

Small surface cracks in the hot plug, extending from the opening to approximately 8,O mm (0.312 in) in length can be ignored. However, if any severe cracks appear on the face of the hot plugs before attempting to remove it, closely inspect the cylinder head for signs of cracks, particularly between the inlet and exhaust valve seats. Such cracking indicates that the engine has overheated, usually through lack of coolant, and the cylinder head should be scrapped.

121

2.50 LITRE DIESEL ENGINE

16. To remove a hot plug support the cylinder head, face downwards on two pieces of timber and insert a thin soft metal drift through the injector shroud throat and tap the hot plug from the inside. Once removed, a faulty hot plug cannot be restored and must be scrapped.

ST1428PJ B - Plug

17. If the injector shroud is damaged using a 13 m m

(1.05 in) t~all o u t towards the injector bore.

STl422M

Fitting hot plugs

20. Fit the hot plugs by tapping with a hide-faced mallet, and locate with a new roll pin. If the hot plugs are loose in t h e cylinder head they may be retained with a little grease.

21. When fitted, the hot plugs must be checked with a dial test indicator to ensure that they do not protrude above the level of the cylinder head face more than 0,76 mm (0.003 in) and are not recessed below the level of the cylinder head face more than

0.025 m m (0.001 in).

17 fJ

,-. .

ST1 429M n

Fitting shrouds

18. Thoroughly clean out the combustion chamber.

Thc hole in the side of the injector shroud is for manufacturing purposes only bur at the same time can be used as a guide when rcfitting the shroud.

19. Turn the cylinder head lace down. Smear a little oil on the shroud and insert into the cylinder head with the hole pointing towards the centre of the cylinder hcad, and drift into position.

22. Check the valve guides lor wcar by inserting a new valve in the appropriate guide 8 mm above the seat. If movement across the head exceeds 0,15 m m (0.006 in) renew the guide.

23. Inspect the valves and discard any that arc burnt, bent or distorted. Check the stems for wear by inserting a new guide.

*Area: is exces>;i.,re, discard the valve. Valve faces that are pitted or ridged but otherwise serviceable may be refaced.

24. Renew push rods that are bent or have worn or scored ball o r socket ends.

2.50 LITRE DIESEL ENGINE 12

Whilst this is rarely neccssary the procedure is nevertheless as follows:

25. Using an 8 mni taper tap, cut a thread 30 mm

(1,2 in) deep in the combustion face end of the tube to be removed.

26. Screw an appropriate bolt into the tube and press out the tube as illustrated.

27. Smear both ends of a new tube with silicone rubber sealant ancl press i t into the cylinder head. chambers face downwards. Since the inlet and exhaust valve guides are dimensionally different it is important that the correct-guides are fitted to the appropriate ports.

31. Lubricate ncw guides with engine oil and using special drift 600959 for the exhaust and 601508 for the inlet valve guides or suitable alternatives, drive in the n e w guides until the shoulder is flush with the casting.

ST1444M

I ,

Renew valve guides

28. Support the cylinder head, combustion chamber uppermost on pieces of timber of sufficient thickness to allow clearance for the valve guides to be driven out.

29. Using special drift 274400 for inlet guides and

274401 for exhaust guides or suitable alternatives drive out the old guides from the combustion face side.

Reface cylinder head valve seats

32. Damaged or worn valve seats can be refaced provided they are not abnormally wide due to repeated refacing operations. See instruction 43.

A. Correctly seated valve

B. Undesirable condition

C. Method of rectification

,. ”.

’. ii. ,..

‘

1121

2.50 LITRE DIESEL ENGINE

33. The special set of hand tools recommended for refacing include expandable pilots that fit tightly into new or worn guides to ensure that the valve seat is concentric with valve guide. The refacing tool has tungsten carbide cutters and can be used to cut a seat in a new exhaust seat insert.

34. Select the correct expandable collet for the valvc guide concerned i.e. 8 mm for inlet guides and 8,5

35. mm for exhaust.

Loosely assemble the collet, expander and nuts.

Ensure that the chamfered end of the expander is towards the collet.

38. Use cutter MS 621 and ensure that the cutter blades are correctly fitted to the cutter head with the angled end of t h e blade downwards facing the work, as illustrated. Check that the cutter blades are adjusted so that the middle of thc blade contacts the area of material to be cut. Use thc key provided i n the hand set MS 76.

ST1440 M

36. Insert thc assembled pilot into the valve guide lrom the combustion face side of t h e cylinder head until the shoulder contacts the valve guide and the whole of the collet is inside the valve guide.

37. Expand the collet i n the guide by turning the tommy bar clockwise whilst holding the knurled nut.

ST1439M

39. Fit the wrcnch to the culter head and turn clockwise using only very light pressure. Continue cutting to approximatcly t h c centre of the existing seat.

40. To check the effectiveness of the cutting opcration use engineers’ blue or a feelcr gauge maclc from ceilophane.

41. Smear a m a l l quantity of cngineers’ blue round thc valve seat and revolve

11 properly ground valve against the seat. A continuous fine line should appear round the valve. If there is a gap of not more thar !2 it can be corrected by lapping.

2.50 LITRE DIESEL ENGINE

1121

,A.-.

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-4

42. Alternatively, insert a strip of cellophane between the valve and seat, hold the valve down by the stein and slowly pull out the cellophane. If there is drag the seal is satisfactory in that spot. Repeat this in at least eight placcs. Lapping-in will correct a small open spot.

43. After several trueing-up or lapping-in operations valve seats may have an excessive width which can be reduced by obtaining special correction cutters which narrow the seat by removing metal from the top and bottom of the seat. A 60" cutter is recommended for bottom narrowing and for top narrowing use a 30" cutter.

.. . .

Renew inlet and exhaust seat inserts

44. Hold the cylinder head firmly in a vice, wear protective goggles and grind the old insert away until thin enough to be cracked and prised out.

Take care not to damage the insert pocket.

45. Remove any burrs and swarf from the pocket.

Failure to do this could cause the new insert to crack when being fitted.

36. Assemble the new exhaust insert to the replacer tool number 530625 so that the chamfered edge of the insert is leading. Using a suitable bolt and nut draw the insert into the cylindcr head pocket.

47. Since no tool is available for the inlet scat, use a suitable adaptor to press-in the new seat. Cut a new

45" seat using cutter MS 621.

/ L

ST691 M

Inlet valve seat face -

Exhaust valve seat facc -

Inlet valve face - - %"

Exhaust valvc face - - %"

Lap-in valves

49. To ensure a gas tight scal betwccn thc valvc facc and valve seat it is ncccssary to lap-in the appropriatc valve to its seal. It is essential to keep the valve idcntificd with its seat once the lapping-in opcration has bccn completed.

50. Unless the faces to bc lappcd are in poor condition it should only be necessary to usc fine valve lapping paste. Smear a m a l l quantity of paste on the valve face and lubricate the valve stem with engine oil.

51. Insert the valve in t h e appropriatc guide and using a suction type valve lapping tool employ a light reciprocating action while occasionally lifting the valve off its seat and turning i t so that the valvc returns to a different position on the seat.

Reface valve seats

. .,

48. Valves that are satisfactory for further service can be refaced. This operation should be carried out using a valve grinding machine. Only the minimum of material should be removed from the valve face to avoid thinning of t h e valve edge. The valve is refaced correctly when all pits are removed and t h e face concentric with the stem.

1121

2.50 LITRE DIESEL ENGINE

52. Continue the operation until a continuous matt grey band round the valve face is obtained. To check that the lapping operation is successful, wipe off the valve paste from the valvc and seat and make a scries of pencil lines across the valvc face.

Insert the valve into the guide and while pressing the valve onto t h e seat rcvolve the valve a quarter turn a few times. If all the pencil lincs are cut through no further lapping is required.

53. Wash all traces of grinding paste from the valves and cylinder head seats.

Assembly valves to cylinder head

54. Insert the inlet valves into the guides and fit new oil seals ~ i t h locates i n the groove in the valve guide.

55. Insert the exhaust valves and fit the oil seals with the ste?ped exterior. They are largcr than thc inlet valve scals.

56. Fit the doublc valve spring and cup to each valvc in turn arid using valve spring compressor, 276102 or a suitable alternative, secure the assembly with the multi-groove butting cotters.

ST1431M

59. Examine the rocker shaft for wear and discard if the bearing surfacc is worn more than 0,025 mm

(0.001 in).

60. Inspect t h e rockers and discard if the pads arc worn. It is not permissible to grind pads in an attempt to reclaim the rockers.

61. Renew bushes if the clearance betwecn shaft and bush is in excess of 0,101 to 0,127 m m (0.004 to

0.005 in).

62. Press in replacements ensuring that thc prc-drilled oil holes coincide with the holes in t h e rockers.

The following cross section o f a rocker shows thc oil drillings.

ST1430M

OVERHAIJL ROCKER SHAFT ASSEMBLY

Dismantle and inspection

57. Remo*:e the locating screw and washer from thc number two rocker bracket and withdraw all the componcnts from the rocker shalt.

58. Remove t h e locknuts and adjustment screw5 from t h e rockers.

ST1433M

63. Using a A4 reamcr 1 3 3 nim

0,2 m m (0.530 in

0.001 in) finish the bushes and clear swarf from the oil holes.

64. Examine the ball-end of t h e adjusting screws and discard any that are worn. Regrinding is not permissable. Check the thrcads for damage and that the oil relief drilling is clear.

. i c -

- 4

Assemble rocker shaft assembly

65. Check that thc oil-ways in t h e rocker shaft are clcar and fit number two rocker shaft bracket

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L l l l U to the shaft

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66. Using new spacers and springs, assemble the rockers and brackets to the shaft as illustrated, ensuring that t h e rockers move freely on thc shaft.

Note th.jt double spacers are fitted each side of the centre pedestal.

67. Fit the tappet adjustment screws and lock nuts to the rockers.

68. Invert the rocker assembly and locate it on the rocker cover to prevent it falling apart. Place the reconditioncd cylinder head and rocker assembly to one side ready for fitting to the engine.

2.50 LITRE DIESEL ENGINE

Si1432M

. ..

.. .

...

REMOVE AND OVERHAUL THE FLYWHEEL

1. Remove the flywheel retaining bolts and withdraw the flywheel and reinforcing plate.

2. Wear or scores on the flywheel clutch face can be corrected by machining provided that the overall width of t h e flywheel is not rcduccd bclow

36,96 mm (1.453 in).

3. Check that the flywhccl has not been previously machined.

4. Examine the ring gear teeth and if chipped or worn thc gcar can be renewed.

Reface the flywheel

5. Remove the clutch location dowels.

6 . Machine thc flywheel over the complete clutch face removing only thc minimum niaterial necessary to achieve a smooth flat surface parallel with the crankshaft mating face and within the above width dimensions and fit new dowels.

Renew the ring gear

7. Drill a 8,O mm (& in) hole betwecn the root of any two teeth and t h e inner diametcr of the starter ring decp enough to weaken the ring. Do not allow the drill to enter the flywheel.

2.50 LITRE DIESEL ENGINE

8. Secure the flywheel in a soft jawed vice and cover it with a cloth to protect one from personal injury.

Place a cold chisel above the drilled hole and strike it sharply to split the ring gear.

ST701 M

\ ‘

9. Heat the new ring gear uniformally to between

225°C and 250°C but do not exceed the higher figure.

10. Place thc flywheel, clutch face down, on a flat surface and locate the heated flywheel with the square cdge of teeth downward towards the flywheel clutch face and chamfered edge of the teeth uppermost.

1 I . Press the starter ring firmly against the flange until the ring contracts sufficiently to grip the flywheel.

Allow the ring gear to cool naturally. Do not hasten cooling in anyway.

Dismantle oil pump

3 Bend back the lock wa\her and release the n u t securing the strainer to the oil pump body and remove the strainer and sealing ring.

4. Remove four bolts and washers and l i f t off the oil pump cover and lift out the driven and idler gears.

(a) driven gear

(b) idlcr gear

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ST 928M

REMOVE AND OVERHAUL OIL PUMP -

1. Remove the sump.

2. Bend back the lock washers and remove the two bolts securing the oil pump to the crankcase.

Withdraw t h c oil pump complete with strainer and oil pump drive shaft.

ST591 M

2.50 LITRE DIESEL ENGINE

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5. Remove t h e oil pressure relief valve plug and sealing washer. Withdraw the relief valve spring, plunger and ball.

NOTE: Later pumps have ten toothed gears and no relief valve ball.

Overhaul the oil pump

6. Examine the gears for wear, scores and pits. If the gears appear serviceable check for end-float as fo 1

I0 ws :

7. Clean t h e pump body and assemble the gears.

Place a straight edge across [he pump body face, as illustrated, and using a feeler gauge, measure the clearance between the body and gears. The correct clearances are as follows:

8. Idler gear 0,07 to 0,015 mm (0.003 to 0.006 in).

9. Driven gear 0,05 to 0,12 mm (0 002 to 0.005 in).

, .

I:-

ST911M

13. A scored ball valve seat can be restored by using a locally made lapping tool by silver soldering a new ball (part number 3748) onto a length of suitable tube.

14. Install the tube in a drill and lap-in using coarse grinding paste. Finally hand-lap the seat with fine paste using the same diabalo method as for lapping valves.

15. Thoroughly wash the pump body to rcmovc all traces of grinding paste.

,_..

10. Gears must be renewed in pairs. A worn, but serviceable gear, must not be matched with a new one.

11. If necessary renew idler gear spindle by drilling-out the peened over end of the spindle so that t h e spindle can be withdrawn from the pump body. To ensure squareness w h e n fitting the new spindle, assemble it into t h e pump body with the two gears.

Fit the cover and secure with the four bolts.

Support the pump body and peen over the end of the new spindle. Remove the cover and gears and check security of the spindle.

12. If worn, remove the idler gear bush and press in a replacement. Drill the lubrication hole 3.17 mm

(0.125 in) and ream the bush to 12,7 m m (0.500 in) diameter.

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ST694M

Assemble the oil pump i6. Fit the idler gear to the spindie.

17. Fit the driven gear with plain part of the bore uppermost. See illustration after instruction 9.

18. Smear t h e joint face of the body with jointing compound and f i t the cover over the dowels and the strainer bracket and secure with the four bolts and spring washers.

19. Hold relief valve bore vertically and insert the ball followed by the plunger with the ball seat end first.

Fit t h e spring, sealing washer and plug.

21. Secure the lower end of the bracket to the strainer with the single bolt, spring and plain washer.

121

2.50 LITRE DIESEL ENGINE

REMOVE AND OIL

Type

I . Remove the sump.

2. Bend back the lock washers and remove the two bolts securing the oil pump to the crankcase.

Withdraw the oil pump complete with strainer and oil pump drive shaft.

Dismantle oil pump

3. Bend back the lock washer and release the nut securing the strainer to the oil pump body and remove the strainer and scaling ring.

4. Remove four bolts and washers and lift off the oil pump cover and lift out the driven and idler gears.

(a) driven gear

(b) idler gear

5 . Remove the oil pressure relief valve plug and sealing washer. Withdraw the relief valve spring and plunger.

Overhaul the oil pump

6. Examine the gears for wear, scores and pits. If the gears appear serviceable check far end-float as follows:

7. Clean the pump body and assemblc the gears.

Place a straight edge across the pump body face, as illustrated, and using a feeler gauge, measure the clearance bctween the body and gears. The correct clearances arc given in the Data section 05 book one.

ST1635M

ST1636M

8. Gears must be renewed in pairs. A worn, but serviceable gear, must not be matched with a new one.

9. If necessary renew idler gear spindle by drilling-out the peened over end of t h e spindle so that the spindle can brt withdrawn from !he pump hody. To ensure squareness when fitting the new spindle, assemble it into the pump body with the two gears.

Fit the cover and seclire with four bolts. Support t h e pump body and peen over the end of the new spindle. Remove t h e cover and gears and check security of the spindle. continued

2.50 LITRE DIESEL ENGINE

1121

Assemble the oil pump

10. Fit the idler gear to the spindle.

11. Fit thc driven gear with plain part of the bore uppermost.

ST1637M

REMOVE TIMING BELT, PULLEYS AND COVERS

Remove front cover

1. Remove the four bolts and remove the front cover vent and wading plug bracket, gauze and gasket.

2. Remove nine timing cover bolts, but do not withdraw centre bolt from the cover since there i s a fibre washer on t h e bolt behind the cover. Remove the cover and joint washer and retrieve the fibre was her.

3. Prise out the crankshaft seal.

Remove timing belt and pulleys

4. Slacken and remove t h e camshaft retaining bolt, special washer and ‘0’

5. Slacken and remove the distributor pump timing pulley n u t .

6. Slacken the belt tensioner clamp nuts and remove the belt. Remove the clamp n u t and withdraw the tensioner assembly.

7. Use the centre part of special tool 18G145711 as illustrated, and withdraw the distributor pump pulley.

12. Smear the .joint face of the body with jointing compound and fit the cover over the dowels and sccurc with the four bolts and spring washers.

13. Hold relief valve bore vertically and insert the plunger with the solid cnd first. Fit the spring, sealing washer and plug.

14. Fit the oil strainer sealing ring to the pump body followed by t h e lock washer and strainer. Tighten the strainer retaining nut so that whcn fitted the strainer is positioned parallel t o the sump baffle plate. Secure the nut with the lock washer tab.

ST1456M

8. Use special puller tool 18G1464/2/6, a s illustrated and withdraw the camshaft pulley.

)121

2.50 LITRE DIESEL ENGINE

9. Withdraw t h e crankshaft pulley using complete tool 18G1464/2 and button 18G1464/5.

ST1457M

Remove distributor pump (D.P.S. Pump)

10. Remove the high and low pressure pipes from the

D.P.S. pump and injectors. (If not already removed) and cover, not plug, the ports.

11. Disconnect the pump operating link from the lever on the bracket. (If not already removed).

12. Remove the nut and bolt securing the rear of the pump to thc support bracket.

13. Remove the three nuts retaining the pump to the front cover and withdraw the pump and joint washer.

KEY TO TIMING GEAR AND COVER ASSEMBLY

1. Fan blades

Spacer

Fan pulley

4. Special bolt -

5 .

6. engines.

Crankshaft pulley

Wading plug

7. Timing cover vent

8. Inspection cover

9. Front cover plate

10. Front cover plate oil scal

11. Water pump

12. Water pump joint washer

13. Cover

14. Timing belt

15. D.P.S. pump pulley

16. Camshaft pulley

17. Jockey pulley (tcnsioner)

16. Coolant gallery joint washer

19. Front cover to cylinder block joint washer

20. Front cover plate joint washcr

21. Camshaft front cover oil seal

22. Crankshaft cover oil seal

23. Triangular joint washer

24. Fibre washer

REMOVE TAPPETS, ROLLERS AND GUIDES

1. Remove the eight tappet guide locating bolts from the right-hand side of the cylinder block.

CAUTION: Do not remove the tappet guides before the rollers otherwise the rollers may fall behind the camshaft.

2. Using long nosed pliers or a suitable bent length of wire lift out t h e tappet slides and identify them with their respectivc guides for possible refitting.

14. Remove the retaining bolts and remove the front cover and gaskets from the cylinder block. Prise out the old oil seals.

2.50 LITRE DIESEL ENGINE

3. Lift out the tappet rollers and mark the side facing the front of the engine for possible reassembly.

4. Lift out the guides and retain w i t h t h e i r respective slides and rollcrs. If the guides are difficult to remove use special tool 530101A.

5 . Carcfully examine all parts and discard any that are worn o r damaged.

Examine

4. Inspect the components for wear and damage and renew as necessary.

5 . To check thc rotor to body clearance, f i t the rotor to the body and with feeler gauges measure the clearance at the narrow point between the rotor and body. The correct clearance is 0,05 m m

(0.002 i n ) .

6. Check the clearance between the rotor and end plate by placing a straight across the body and with feeler gauges measure the clearance between the straight edge and rotor. The correct clearance should be 0,lO to 0,12 mm (0.004 to 0.005 in).

Assemble

7. Fit t h e rotor blades to t h e rotor with thc radius outwards and insert thc rotor into the body.

8. Place a new ‘0’ i n position in the body groove and fit t h e end platc and sccure with the four bo 1 t s tight en i n g eve n I y

9. When fitting pump to engine use a new joint washer and ensure that t h e drive slot fits correctly over the coupling drivc pin.

ST699M

REMOVE ANI) OVERHAUL VACUUM PUMP

Dismantle

1 . Reniove the pump from the engine.

2. Remove the four bolts securing the end plate and withdraw the end plate and ‘0’

3. Tap the shaft-end of the rotor t o remove it from the pump body.

REMOVE AND OVERHAUL SKEW GEAR

COUPLING

The coupling can be overhauled without separating i t from the skew gear.

Remove skew gear assembly

1. Remove the oil filter housing complete with filter and joint washer.

2. Remove the skew gear bush locating screw.

3. Using long-nosed pliers l i f t out thc skew gear assembly.

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ST868M

ST614M

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Dismantle

4. With circlip pliers remove t h e retaining circlip.

5 . Withdraw the seal collar and remove the inner and outer seals.

6. Remove the lower circlip and withdraw the sleeve.

Assemble

7. Reassemble the coupling with a n y new parts necessary ensuring that the sleeve fits correctly over the lower cross-pin and secure with the circlip.

8. Lubricate and fit new seals to the collar and insert into the coupling and retain with the circlip. Make sure that the seals are properly located since damaged or misplaced seals could cause reduced engine oil pressure.

2.50 LITRE DIESEL ENGINE

1121

RENEW SKEW GEAR COUPLING

Dismantle

1. Position the skew gcar and coupling assembly in a press and support it, as illustratcd, with 18G705-1A o r suitable metal bars.

2. Insert a suitable mandrel betwccn the press ram and end of the coupling shaft and press out the coupling from the skew gear.

.' REMOVE THE CAMSHAFT

1 . Since the camshaft sprocket has already been removed, remove the two bolts and the camshaft thrust plate and carefully withdraw the camshaft.

. .

.. -

Inspect the camshaft

2. Discard the canishaft if any of the following visual defects are evident. Scored, w o r n , pitted or chipped cams. Worn, corroded and discoloured journals. Worn and chipped gear teeth.

Fit new coupling to skew gear

3. Dismantle the new coupling, as described in

'Coupling Ovet-ha~il'. in thc assembled condition there is no suitable surface for the press tool to bear upon.

NOTE: See 2.5 litre petrol engine supplement for details of the latest skew gear bush retension.

2.50 LITRE DIESEL ENGINE

4 Dismantle also the old coupling and use the sleeve to manufacture a suitable press tool. Use a round section file to increase the depth of t h e cross-pin slot so that i t will not bear upon the cross-pin when used to press in the new coupling. Weld a suitable length of steel bar or tube to the sleeve to complete the tool.

5 . Fill the annular groove round the splines of the coupling with silicone rubber sealant.

6 . Assemble the skew gear and coupling with the manufactured press tool in position inside the coupling a n d place under the press and slowly press in the new coupling. Clean o f f surplus sealant and swarf from the internal splines of the skew gear.

REMOVE THE CONNECTING-RODS AND PISTONS

During the following instructions it is important that all components are kept in related sets and the pistons are identified with their respective bores.

1. Turn the crankshaft to bring the connecting-rod caps to an accessible position and remove each cap and lower shell in turn. Note that the connecting- rod caps arc numbered one to four.

2. Push each piston assembly up the bore and withdraw from the cylinder block. Assemble the caps and shells to the connecting-rods and place to one side for inspection with the cylindcr block at a later stage.

REMOVE AND INSPECT CRANKSHAFT

1. Remove the eight bolts securing the flywheel housing to the cylinder block and remove the housing and rear main bearing oil seal, and ‘0’ ring.

The ‘0’

7. Reassemble the new coupling as described under

‘Coup1 i ng Overhaul ’ .

ST7 1 8M

,.“.:2 *

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2.50 LITRE DIESEL ENGINE

1121 out the crankshaft. Collect the bearing shells from the bearing saddles and the thrust washers from the centre saddle.

EXAMINE AND OVERHAUL THE CYLINDER

BLOCK

1. Remove the four jet tubes, see Engine assembly for illustrations and details.

Degreasc the cylinder block and carry out a thorough visual cxamination checking for cracks and damage. To check the main bearing caps and saddles for distortion. Fit the main bearing cap without bearing shclls and tighten to the correct torque. Slacken and remove the bolt on one side of each bearing cap and check with a feeler gauge that no clearance exists at the joint face between thc cap and saddle.

-ST719M

3. Degrease t h e crankshaft and clear out the oil ways, which can become clogged after long service.

4. Examine visually, the crankpins and main bearing journals, for obvious wear, scorcs, grooves and overheating. A decision at this stage should be made as to whether the condition of the shaft is worth continuing with more detailcd examination.

5 . With a micrometer, measure and note the ovality and taper of each main bearing journal and crankpin as follows:

6.

Ovality - Take two readings at right angles to each other at various intervals.

The maximum ovality must not exceed 0,040 mm

(0.0015 in).

7. Taper - at both ends of the main bearing journal and crankpin.

The maximum permissable taper must not cxcccd

0,025 mm (0.001 in).

8. To check for straightness, support thc front and rear main bearing journals in ‘V’ blocks and position a dial indicator to check the run-out at the centre main bearing journal. Run-out must not exceed 0,076 mm (0.003 in) taking into account any ovality in the centre journal.

The overall allowable wear limit should not exceed

0,114 mm (0.0045 in) for main bearing journals and 0,088 mm (0.0035 in) for crankpins.

A crankshaft worn beyond the limits of maximum taper, ovality and overall wear can be ground to

0.25 m m (0.010 in) undcr size.

NOTE: Fer regrindhg inf3r1m?icr. see page 8 2.25 litre petrol and Diesel engine overhaul.

Inspect cylinder bores

2. Measure t h e cylindcr borcs for ovality, taper and general wear, using any suitable equipment.

However, an inside micrometer is best for checking ovality and a cylinder gauge for taper.

3. Check the ovality of each bore by taking measurement at t h e top of the cylinder just below t h e ridge at two points diametrically opposite. The difference between the two figurcs is t h e ovality of t h e top of the bore. Similar measurements should be made approximatcly 50 mm (2.0 in) up from the bottom of the bore

$0 that t h e overall ovality may be determined.

4. Thc taper of each cylinder is dctermined by taking measurements at the top and bottom of each bore at right angles to the gudgeon pin linc. The difference between the two measurements is the taper.

5. To establish maximum overall bore wear, take measurements at as many points possible down the bores at right angles to the gudgeon pin line. The largest recorded figure is the maximum wear and should be compared with the original diameter of the cylinder bore.

Maximum permissible ovality 0,127 mm (0.005 in).

Maximum permissible taper 0,254 mm (0.010 in).

Maximum pcrmissiblc overall wear 0,177 mm

(0.007 in).

2.50 LITRE DIESEL ENGINE

If the above figures are exceeded the cylinders must be rebored or sleeved depending upon the general condition of the bores and amount of wear.

Alternatively, if the overall wear, taper and ovality arc wcll within t h e acceptable limits and the original pistons are serviceable new piston rings may be fitted. It is important however, that t h e bores arc deglazed, with a hone, to give a cross- hatched finish to provide a seating for the new rings. I t is vital to thoroughly wash the bores afterwards to remove all traces of abrasive material. inspect camshaft bearings

6. Measure thc internal diameter of each camshaft bearing at several points using an internal micrometer. A comparison of the bearing diameters with those of the respective camshaft journals will give the amount of clearance. The bcarings should be renewed if the clearance exceeds 0,0508 mm (0.002 i n ) . Or, in any event, if they are scored or pitted. This work should only be entrusted to line boring specialists.

Check crankcase main bearings

7. Discard scored, pitted, cracked and worn bearing shells.

8. To determine the maximum wear, assemble the main bearing shells and caps to the crankcase and tighten the bolts to the corrcct torque figure.

9. Using a n inside micrometer, measure each bearing at several points and note the greatest figure. The maximum wear is the difference between this figure and the smallest diameter of t h e corresponding crankshaft journal. The main bearing running clearance is in the data section.

10. The bearing clearances may also be determined by using ‘Plastigauge’. Since this method requires the crankshaft to be fitted to the crankcase, the procedure is described under engine assembly.

Fit cylinder sleeves

Cylinder bores that cannot be rebored can be restored by fitting sleeves to enable standard size pistons to be fitted. Sleeving one cylinder only will distort the adjaccrrt bore so sleeving must be carried out in pairs, i.e. cylinders 1 and 2 or 3 and 4.

11. M2chine the cylinder bores to accept the sleeves to

94,425

0,012 mm (3.7175

0.0005 i n ) . This will givc the sleeve a 0,076 to 0 , I14 mm (0.003 to

!!.!!!!45 in) interference fit.

12. Press the sleeves squarely into the bore using a pressure of two to three tons. Excessive pressure could damage the sleeve and cylinder block. The sleeves must not be proud of the cylinder block top face or more than 2,54 mm ( 0 , l O in) below the surface.

13. Bore and hone the sleeves to accommodate the pistons with the required clearances, see piston and connecting-rod examination.

PISTON AND CONNECTING-ROD INSPECTION

The following checks relating to pistons and rings must also be carried out prior to fitting new pistons to rebored and sleeved cylinder blocks.

Until it is decided if new components are required all parts must be kept in their related sets and the position of each piston to its connecting-rod should be noted.

1. Remove the piston rings and gudgeon pin from each piston and detach the connecting-rod.

ST1452M

2. Original pistons - components and carry out a visual examination of the pistons and rings and discard any which art‘ u n se rv i cea b I e. Pis tons w h ic h ap pe it r service ab I e should be subjected to a more detailed examination described under ‘New Pistons’.

2.50 LITRE DIESEL ENGINE

3. New Pistons engines at t h e factory are specially graded to facilitate assembly. The grade letter on the piston crown should be ignored when ordering new pistons. Genuine Land Rover service standard size pistons are supplied 0,025 mm (0.001 in) oversize to allow for production tolerances on new engines.

When fitting new pistons to a standard size cylinder block the bores must be honed to accommodate the pistons with the correct clearances. In addition

Land Rover pistons are available 0 5 0 and 1,Ol m m

(0.020 and 0.040 in) oversize for fitting to rebored cylinder blocks.

Clearance limits for new standard size pistons in a standard cylinder bore measured at right angles to the gudgeon pin are in the “General specification data” section.

When taking the following measurements the cylinder block and pistons must be a t the same temperature to ensure accuracy.

3 . Using a suitable micrometer measure the pistons at the bottom of the skirt at right angles to the gudgeon pin.

5. With an inside micrometer or cylinder gauge measure the diameter of the bore at approximately half-way down and note the reading.

6. The clearance is determined by subtracting the piston diameter from the bore diameter.

Inspect piston rings

8. Check gap When chccking the ring gap in worn bores, but are neverthclcss within the acceptable taper and ovality limits, the ring must be inserted squarely into the bottom of the bore at the lowest point of the piston travel. To ensure squareness of the ring push the ring down the bore to the correct position with a piston. With newly machincd bores, the ring may be inserted squarcly into any position in the bore.

9. Using an appropriate feeler guage check the gaps of all the rings, in turn, including the oil control ring assembly.

The correct gaps are listed in the Data Section. If any gap is less than that specified, remove thc ring, and file the ends squarc, whilst holding the ring in a filing jig o r vice. Should any gap be excessively wide and not likely to close-up to within the specified limits when hot, an ovcrsizc ring shou!d be fitted.

7 . If garige equipment is not available the clearance can be assessed by placing a long, suitably sized, feeler gauge down t h e thrust side of the bore and inserting the appropriate piston, ‘upside down’, in the bore and position it with the gudgeon pin parallel to the crankshaft axis. Push the piston down the bore and stop at the tightest point and whilst holding the piston still, slowly withdraw the feeler gauge. If a steady resistance of approximately 2,s kg (6 Ibs) is felt, the clearance is satisfactory.

2.50 LITRE DIESEL ENGINE

Check piston ring side clearance

10. It is important that clearances are correct. Rings that are too tight will bind when hot, imparing the radial pressure causing possible loss of comprcssion. Excessive clearancc will allow the rings to rock in the grooves and the resulting pumping action could cause excessive oil consumption and eventually broken rings.

11. Fit the oil control ring to t h e bottom groove. Fit the unpolished compression ring with the word ‘TOP’ uppermost to the second groove. Insert the polished chrome ring with an internal chamfer and the word ‘TOP’ uppermost to the top groove.

12. Alter fitting each ring, roll it round the piston groove

10 ensure that i t is free and does not bind.

13. Using an appropriate feeler gauge check the clearance betwcen the rings and piston grooves.

Clcarances in excess of 0,012 to 0,152 mm (0.004 t o

0.006 in) are unacceptable and the ring and or the pistons should be renewed.

Compression rings - to 0,011 mm (0.0025 to

0.0045 in).

Oil control ring - to

0.0025 in).

ST1449M

Inspect gudgeon pins

14. Check the gudgeon pin for wcar, cracks, scores and overheat i n g .

15. The gudgeon pin fit in the piston must be tight push f i t at a lcmperature of 68°F (20°C). Chcck the gudgeon pin for ovality and taper using a micrometer.

Connecting-rod inspection

16. Check the connecting-rods and caps for distortion as follows; f i t the correct cap, less the bearing shells, to each connecting-rod as denoted by the number stanipcd near the j o i n t faces. This number also indicates the crankshaft journal to which it must be fitted.

17. Tighten the nuts to the correct torque and release the nut on one side only. Check, with a feeler gauge, that no clearance exists between the joint faces. If there is a gap the connecting-rod is distorted and should be renewed.

ST716M

18. Use an accurate connccting-rod alignment gauge to check thc rods for bend and twist. The maximum allowable for both conditions must not exceed

0,127 m m (0.005 in).

19. Examinc and check the small-end bush for wear. If necessary rcnew the bush. The correct clearance of the gudgeon pin in the small-end bush is given in

“Gencral specification data”.

20. When rcnewing a bush ensure that the oil hole in the bush lines up with the hole in the connecting- rod. Finish the bush to the correct size and clearance.

21. Connecting-rod bearings that are worn, pitted, scored and show signs of ovcrheating must be discarded. If more than one of the bearings show these signs they must all bc rcncwed. When fitting new o r used bearings to serviceablc crankpins the clearances must be checked.

!f-

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Connecting-rod bearing nip and clearance

New bcaring halves are supplied with a protective coating and must be degreased before fitting.

22. Fit the bearing halves to the connecting-rod and cap and secure the assembly with the correct torque. Slacken the nut on one side only and check the clearance between the joint faces with a feeler gauge. f>:,

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2.50 LITRE DIESEL ENGINE

1121

+.‘

’:

-1 * ::

‘j.

. .

The clearance should be between 0,lO and

0,20 mm (0.004 and 0.008 in). The bearing nip can be adjusted by t h e selective assembly of the bearing shells which are available in slightly varying thickncsscs. Do not file or machine the caps o r rods to vary t h e bearing nip. Make a final check to prove the clearance by inserting a 0,063

(0.0025 in) shim paper between the crankpin and one half of the bearing and tightening to the correct torque. The connecting-rod should resist rotation and move freely with the shim paper removed.

As an alternative, the bearing clearances can be determined by using ‘Plastigauge’ which consists of a t h i n piece of plastic material a few hundreds of a millimeter or thousands of an inch in diameter.

When the material is flattened by being squeezed between the bearing and crankpin the width of the plastic is measured by a scale gauge which indicates the clearance.

23. Wipe any oil from the crankpins and place a piece of ‘Plastigauge’ across the centre o f the bearing in the connecting-rod cap. Assemble the rod to the appropriate crankpin and tighten to the correct torque. Do not rotate thc connecting-rod or crankshaft during this operation.

24. Remove the connecting-rod cap and bearing shell and using the scale supplied measure thc flattened

‘Plastigauge’ a t its widest point. The graduation that most closely corresponds to the width ol’ the

‘Plastigauge’ indicates the bearing clcarance.

The correct clearance with new or overhauled components is 0,019 to 0,063 mm (0.0007 to

0.0025 i n ) .

25. Wipe off the ‘Plastigauge’ with an oily rag. Do not scrape off otherwise it may damage the crankpins.

Connecting-rod end-float

Assemble pistons to connecting-rods

27. The piston must be assembled with the point of the

LV’, on the same side as the bearing shell location slots in the connecting-rod.

28. Inscrt a circlip in one side of the gudgeon pin boss and assemble the piston to the connecting-rod with the gudgeon pin. Secure the assembly with a circlip on the opposite side of t h e piston.

ST 1448 M

2.50 LITRE DIESEL ENGINE

ASSEMBLE ENGINE

FIT CRANKSHAFT ASSEMBLE JET TUBES TO CYLINDER BLOCK

Oil jet tubes arc fitted to lubricate the pistons and bores directly from thc main oil gallery.

1. The jet iubes are 'Handed' and can only be fitted one way. It is important to note that the jet retaining 'bolt' contains a non-return valve and therefore on no account must an ordinary bolt be

4 used.

Clean the recess in the cylinder block using an air line, i f available, to remove any swarf.

Assemble and f i t t h e jet tube assemblies as illustrated ensuring that the pegs locate in the holes in the cylinder block, and that the larger diameter washer fits under the bolt head.

Before tightening the retaining bolts ensure that the small squirt pipes d o not foul the crankshaft or pistons. Firmly tap t h e jet tube assemblies down onto the cylinder block, thus ensuring t h a t the locating dowel is fully home and avoiding any

5 sideways distortion on the retaining bolt. Use

;I tube slightly larger than the bolt head. The old bolt should be discarded and a new bolt fitted.

Whcn thc crankshaft and pistons have been fitted slowly turn the crankshaft and check that no fouling occurs.

A . Early Type B. Latest Assembly.

Main bearing nip and clearance

New main bearing halves are supplied with a protective coating and must be degreased before fitting.

1. Fit the bearing halves in t h e crankcase saddles and caps and secure the caps to the crankcase and tighten to the correct torque. Slacken the bolts on one side of the caps only and, with a feeler gauge, check the gap between the joint faces. The clearance o r nip must be within 0.10 to 0,15 m m

(0.004 to 0.006 i n ) . The bearing nip can be adjusted by selective assembly of the bearing halves available in varying thicknesses. Do not file or machine the caps or saddles to achieve thc correct clearance. Note that thc rcar main bearings are wider than the rcmaining four.

2. To make a f i n d check that the clearance is correct. leave the bearing halvcs in the crankcase saddles and carefully lower the crankshaft into position.

Check each bearing in turn by inserting a 0,063 mni

(0.0025 in) shim papcr between the bearing cap and crankshaft journal and tighten the bolts to the correct torque. If the clearance is correct, thcrc should be a slight increase in the resistance to rotation of the crankshaft.

As an alternative 'Plastigauge' may be used to check the clearance in the same manner a s with the connecting-rod bearings. This material may also be used to determine the amount of wear in used bearings and journals.

ST1789M

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3 . Locate the crankshaft in position on the upper bearing halves in the crankcase and wipe any oil from the ,journals since ‘Plastigauge’ is soluble i n oil. Place a piece of ‘Plastigauge’ across the lower half of each crankshaft journal or lower bearing cap she!l. Fit the cap and tighten to the correct torque. Remove the cap and bearing and using the scale supplied with t h e ‘Plastigauge’ measure the flattened ‘Plastigauge’ at i t s widest point. The graduation that most closely corresponds with the width of the ‘Plastigauge’ indicates the bearing clearance.

The correct clearance with new or overhauled components is included in “General specification data” section. If new bearings are being fitted use selective assembly to obtain the correct clearance.

Wipe off, not scrape the ‘Plastigauge’ with an oily rag from the journals or bearings.

2.50 LITRE DIESEL ENGINE

5. Place the crankshaft in position in the crankcase and mount a dial test indicator to read-off the end of the crankshaft. A feeler gauge may be used instead of an indicator.

6. Determine the end-float by moving the crankshaft away from t h e indicator and zero the dial. Move the crankshaft i n the opposite direction and note the indicator reading. Alternatively measure the clearance with a feeler gauge. The end-float should be 0,OS to 0,15 mm (0.002 to 0.006 in).

Adjust crankshaft end-float

4. Lift o u t the crankshaft and !nSert

21 standard size thrust waiher both sides of thc centre main bcarlng saddle with the grooves towards the crankshafl.

8. Lubricate crankshaft mrlin journals with engine oil and fit the appropriate bearing caps and lower shells to the crankcase with the exception of number five main bearing. Ensure that the caps locate proper!y o v e r the dowels. Using new bo!ts and washers evenly tighten to the correct torque figurc.

Fit rear main hearing cap

9. Ensure that number five main bearing cap is clean and free from old cork seal material.

Attach the cork seal guides number 270304 to the crankcase, as illustrated, and ensure that they are parallcl ihc ciaiikcase edge.

LITRE DIESEL ENGINE

10. To prevent any cork seal material becoming trapped between the bearing cap and crankcase, chamfer the inner edge of the corks 0,40 to

0,80 mm(& to B in) wide as illustrated.

Immcrsc the cork seals in engine oil and fit them to the bearing cap.

Fit rear main oil seal

5369 which should be used is supplied with a former to maintain the correct shape and must not be removed until the scal is to be fitted.

14. Using special seal replacer 18G 134-1 I and wilh the lip side leading drive-in the seal as far as the tool allows. If the tool is not available fit thc scal to the bottom of the housing to ensure squareness.

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11. Fit the bearing cap and lower shell to the crankcase and secure with new bolts and washers and tighten to the appropriate torque.

12. To allow for shrinkage after fitting leave the cork seals standing proud of the crankcase sump face. If possible delay the fitting of the sump for approximately twelve hours and leave t h e seal protruding 2,40 mm (:& in) and then place a m r n I o . > w mm ( % in) washer over the seal and cui off the surplus. If it is necessary to fit the sump immediately, trim the seals off leaving 0,80 mm

( h in) proud, that is, t h e thickness of t h e above washer.

Apply Hylomar SQ32M to the protruding end of the seals.

ST 1828M

Fit flywheel housing -

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L I I C ; I I ~ W I I G L I

16. Examine the seal guide number 18G 1344 and repair any damage that could destroy the seal lip.

17. Lubricate the outside diameter of the seal guide and t h e seal journal with concentrated ‘Oildag’ in a

25% solution with clean engine oil.

1 1 , .

2.50 LITRE DIESEL ENGINE

1121

. I

5 ’

18. Place the seal guide o n the crankshaft flange and, using the two dowels protruding from the cylinder block rear face as a guide to ensure initial squareness, fit the flywheel housing and removc the seal guide. Secure the flywheel housing evenly tightening the retaining bolts.

Fit flywheel housing -

19. In place of the ‘0’

of

Hylogrip 2000 sealant must be applied to the rear facc of the flywheel housing to the dimensions and configuration as illustrated below. The illustration has been produced full size so that a template may be made to facilitate the application of the sealant.

The bead should be 5 3 mm wide and 0,25 mm thick.

20. Fit the housing following instructions 17 to 19.

ST730M

ST1675M

112 I

2.50 LITRE DIESEL ENGINE

FIT THE CONNECTING-HODS AND PISTONS

1. Turn the crankshaft to position numbers one and four crankpins at bottom dead centrc to facilitatc fitting thc connecting-rods.

2. When fitting the connecting-rods and pistons ensure that t h e bolts d o not foul and damage the crankpins. As a precaution it is recommended that rubber or soft plastic sleeves are placed over the threads.

3 . The connecting-rod bolts have essentric heads which locate in a recess in the connecting-rod. It is essential that the head of each new bolt is properly located before tightening.

4. Stagger the compression rings so that the gaps are equidistantly spaced round the piston but, so arranged, that n o gap is positioned on the thrust side of the piston i.e. opposite t h e camshaft. Turn the oil control ring so that the gap is in line with the gudgeon pin.

5 . Lubricate the cylinder walls, piston rings and crankpins. Compress t h e pistons rings with a suitable compressor tool and carefully lower the connecting-rod into the bore ensuring that the piston is assembled in accordance with instruction

27 under “Assemble pistons to connecting-rods”.

Also the point of thc arrow hcaded valve clearance indentation in the piston crown, must face the camshaft side of the engine.

6. Using a soft mallet, sharply tap the piston into the bore so that t h e whole of thc piston is just below the surface of t h e cylinder block.

ST1446M z

2. To check t h e camshaft end-float, fit t h e woodruff key and temporarily fit the cam-shaft pulley and mount a dial test indicator, as illustrated, so that the stylus rests i n a loaded condition upon t h e machined face of the cylinder block. Zero the dial and move t h e camshaft back and forward and note the reading. The end-float should be within 0,06 to

0,13 mm (0.0025 to 0.0055 in). I f the end-float is outsidc these limits, fit different thrust plates until the correct tolerance is achieved.

3 . Remove the test indicator and pulley, and secure the thrust plate with t h e two bolts.

2.50 LITRE DIESEL ENGINE

1 12 1

FIT THE SKEW GEAR

1. Lubricate and insert the skew gear and coupling assembly into mesh with the camshaft gear. Align t h e location hole in the bush and fit a new location screw into ihc cylinder block.

FIT TAPPETS, GUIDES AND ROLLERS

1. If the same parts are being refitted ensure that they are returned to their original positions. Ensure that t h e tappet slides move freely i n the guides.

2. Insert the tappet guides into the cylinder block and align the locating screw holes.

3. Fit the tappet rollcrs ensuring that they are fitted in accordance with the marks made during removal.

N e w rollers, however, may be fitted either way round.

4. Before fitting the tappet slidcs make sure the oilways are clear to the tappet bearing surface, the cross drilling and the oil feed to the push rod.

5. Insert the tappet slidcs with the word 'FRONT' towards the front of the engine.

6 . Secure the tappet guides with NEW Micro encapsulated scie'*s and tighten io ccjr,-eci torque figure. Micro encapsulated screws should also be used on engines where the screws werc originally wired for security.

STl674M"/

FIT THE FLYWHEEL

I I\

1 Examine the flywheel and crankshaft mating faces and remove any burrs or imperfections that could prevent t h e flywheel locating correctly. Check that the dowel is in position. continued

1121

2.50 LITRE DIESEL ENGINE

2 . Offer up the flywheel to the crankshaft and secure with the reinforcing plate and retaining bolts.

Evenly tighten the bolts to the correct torque figure.

3. To check the flywheel run-out, mount a dial test indicator so that the stylus rests, in a loaded condition, on the clutch pressurc face at a radius of

114 mm (4.5 in).

4. Turn t h e flywheel, and check that the run-out does not exceed 0.05 to 0.07 mm (0.002 to 0.003 in).

Should the run-out be excessive, remove the flywheel. and check again for irregularities o n flywheel and crankshaft mating faces and dowel.

Rear cover -

3 . With the lip side leading drive in the new seal using special tool 18G 1456, until the seal is approximately 0,5 mm below the inner face of the cover.

FIT TIMING FRONT COVER, SEALS AND

PULLEYS

1. Fit new cover joint, triangular gasket, and water gallery gasket, to the cylinder block.

2. Fit and secure the rear cover with the eight bolts refering to the chart for location of the various length bolts (in mm). 30

ST1523M

/’

Front cover -

4. Drive in a new seal, lip side leading until flush o r approximately 1 .0 mm below the inner surface using special tool 18G1482. continued

ST617M

2.50 LITRE DIESEL ENGINE 112 1

':it Fit distributor pump (D.P.S.)

5. Fit the camshaft front inspection cover complete with thc D.P.S. pump rear rear support bracket.

Using a new joint washer evenly tighten the six bolts.

6. Fit pump joint washer and loosely secure pump to cover with the three nuts and to the rear support bracket with the single nut and bolt. Position the pump so that the retaining studs are midway in the flange slots.

S T 1 5 2 1 M

Fit crankshaft timing pulley

9. Apply Loctite 518 to the pulley face as illustrated; d o not allow sealant to contact chamfercd face.

Lightly oil the crankshaft and pulley borc and fit the pulley, with timing dot outwards, and drive into position using a suitable tube as a drift.

7. Fit D.P.S. pump pulley, and loosely secure with thc nut.

ST19?1M

Fit camshaft pulley

8. Fit pulley, boss towards engine, and loosely secure with special washer, '0' rings, plain washer and new bolt. DO NOT drive pulley onto camshaft.

Draw pulley on with a slave 10 m m diameter metric bolt, plain washer and nut.

ST1693M

2.50 LITRE DIESEL ENGINE

TIME D.P.S. PUMP AND VALVES

The D.P.S. pump and valves are timed using the exhaust valve peak of number one cylinder. On early engines the exhaust peak position is determined by the relationship of a line, marked E.P. on the flywheel perifery and a timing pointer on the flywheel housing.

The pointer is available under Part Number ERC 2250.

1. Turn the crankshaft in a clockwise direction until the E.P. mark on t h e flywheel lines-up exactly with the pointer. If the crankshaft is inadvertently turned beyond the E.P. mark do not turn it back but continue on round in a clockwise direction until the mark and pointer coincide exactly.

7. Set a dial type torque wrench to 29,O to 23,5 Nm

(21 to 17 Ibs ft) and whilst holding it vertically, insert the drive peg into thc square hole in the tensioner base plate. Tension the bclt and tighten the clamp nuts to the correct torque.

2. Check that the dot o n the crankshaft pulley and the cast-on arrow on the rear cover line-up.

3. Fit the timing belt tensioner assembly and loosely

4. secure with the two nuts (strap deleted o n later models).

Turn the D.P.S. pump pulley clockwise until the dot lines up exactly with arrows in t h e rear cover.

5 . Similarly, turn the camshaft pulley clockwise so that the dot coincides exactly with the cast-on arrow.

6. Fit the timing belt over the crankshaft pulley and whilst keeping the belt under tension, by hand, run the beii over the carnsiiafi puiiey. if iiie beit does not quite mate with the grooves, turn the pulley clockwise the necessary amount. Feed the belt over the pump pulley and if necessary turn the pulley clockwise to locate in the grooves. Keeping a firm grip on the belt pass i t over the tensioner wheel.

8. Rotate the engine TWO complete revolutions.

9. Slacken the tensioncr clamp nuts.

10. Tension the belt again as described in instruction 7 and tighten the clamp nuts to the correct torque.

CAUTION: The double tensioning procedure is imperative, otherwise the belt could fail resulting in serious engine damage. See CAUTION Page 84 and

“Care of beits”.

11. Rotate the crankshaft until, the E . P . mark o n the flywheel and the pointer line-up.

12. Check that the dots on the pump and camshaft pulleys coincide exactly with their respective arrows. If there is any misalignment thc procedure must be repeated.

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13. Remove the plug from the side of the D.P.S. pump and insert gauge tool 18G 1458 and if necessary rotate the pump body until the gauge can be fully inserted and screwed home indicating that the inner disc is centrally positioned with the hole.

14. Evenly tighten the three nuts securing the pump to the cover and the single n u t and bolt to the support bracke t .

15. Align timing pointer on rear of cover, with the scribed line on the pump flange and tighten t h e two screws. If a new pump is being fitted and there is n o scribed line, scribe a line in the centre of the machined area on the pump flange. Align the timing pointer and tighten the screws. On later engines the timing pointer has been deleted and instruction 15 can be ignored.

2.50 LITRE DIESEL ENGINE

112

1. Remove the plug from the flywheel housing and fit t h e body of special tool LST 107 without the pin.

2. Turn the crankshaft in a clockwise direction until t h e E.P. slot in the flywheel is in-line with the hole in the flywheel housing. If the crankshaft is inadvertently turned beyond the E . P . slot, do not turn the crankshaft back but continue on round in a clockwise direction until the pin of the special tool can be fully located i n the flywheel slot.

16. Tightcn the D.P.S. pump timing pulley n u t and thc camshaft pullcy retaining bolt to the correct torque.

17. Remove the timing pointer from t h e flywhecl housing, close the cover and secure with the two nuts.

Time D.P.S. PUMP AND VALVES with slot in flywheel for determining the E.P.

The D.P.S. pump and valves are timed using the exhaust valve peak of number one cylinder. This is determined on later engines by the relationship of a slot in the flywheel periphery and a plugged hole in the flywheel housing through which a flywheel timing pin, special tool number LST 107, is inserted.

3. Fit the timing belt tensioner assembly and loosely securc with the two nuts.

4. Turn t h e D.P.S. pump pulley clockwise until the dot on the pulley lines-up exactly with the cast-on arrow inside the front cover.

5. Similarly, t u r n the camshaft pulley clockwise until t h c dot lines-up with the cast-on arrow in the front covcr.

6. Fit a new timing belt over the crankshaft pulley and whilst keeping t h e belt under tension, by hand, run the belt over the camshaft pullcy. Should thc belt not quite mate with the grooves, turn the pullcy clockwise the necessary amount. Fced the belt over t h e D.P.S. pump pulley and if necessary turn the pulley clockwise to locate in the grooves. Keeping a firm grip on t h e belt, pass i t over the tensioner jockey pulley.

7. Withdraw the special tool timing pin from the flywheel slot.

8. Set a dial type torque wrench to 20.0 to 23.5 N m

(21 to 17 Ibs f t ) and whilst holding it vertically, insert the drive peg into the square hole in the tensioner base plate. Tension the belt and tighten iiie ciamp n u t s to the correct torquc.

9. Rotate t h e crankshaft TWO complete revolutions.

10. Slacken the tensioner clamp nuts.

I 1 . Tension the belt again as described in instruction 8 and tighten the clamp nuts to the correct torque.

2.50 LITRE DIESEL ENGINE

CAUTION: The double tensioning procedure is imperative otherwise the belt could fail resulting in serious engine damage. Also, if a new belt is not attainable and it is necessary to refit the old belt it should be only torqued to 19-24 Nm (14-18 Ibs ft).

15. Evenly tighten the three nuts securing the pump flange to the rear cover and the single nut and bolt to the rear support bracket.

16. Align the timing pointer on thc rcar of the cover with the scribed line on the pump flange and tighten the two screws. If a new pump is being fitted and there is no scribed line, scribe one in the centre of the machined area on thc flange. Align the pointer and tighten the screws. Remove the special tool 18G 1458 and refit plug. The timing pointer has been deleted on later engines.

12. Rotate the crankshaft until the pin of the special timing tool can, once again, bc inserted into the flywheel E.P. slot.

13. Check that t h e dots on the camshaft and D.P.S. pump pulleys coincidc exactly with their respective cast-on arrows on thc rcar covcr. Should there be any misalignment the foregoing procedure must be repeatcd.

14. Remove the plug from the side of the

D.P.S.

pump and insert special tool 18G 1458 and if necessary rotate the pump body until the tool can be fully inserted and screwrd home indicating that the inner disc is centrally positioned with the hole.

STl518M

17. Remove the special tool LST 107 and refit the plug to the flywheel housing.

18. Tighten the D.P.S. pump pulley nut and the camshaft pulley retaining bolt to the correct torque.

Care of belts

1. Drive belts must be stored o n cdge on a clean flat surfacc and in such a manner that bends are not less than 2 in (50 mm) radius.

2. When a belt is handled, it must not be bent at an acute angle or an arc of less than 1 in (25 mm) in diameter, as damage rriay be caused to the glass fibrc reinforcement and premature failure then result.

3. During use, a belt develops a wear pattcrn, thereforc, if it is to be re-used, before removal, mark the direction of rotation, using soft chalk or a similar marker, and refit the belt so that it runs in the original dircction.

4. Belts must be dry and FREE FROM ANY OIL

O R OTHER FLUID CONTAMINATION.

5 . Do not turn the crankshaft by applying leverage to the camshaft pulley or its retaining bolt.

6. To remove a belt always use clean hands, or a recommended tool - g?!,

*<:..I; t'-S

“

2.50 LITRE DIESEL ENGINE

FIT FRONT COVER WATER PUMP AND

CRANKSHAFT PULLEY

1. Place a new joint washer in position and insert the centre 65 mm long bolt into the cover with the fibre washer on thc inside.

2. Fit the cover over the dowels and secure with the remaining various length bolts in accordance with the chart. See “Fit timing rear cover, seals and pulleys”. Tighten evenly to the correct torque.

3. Fit the vent cover gauze and gasket and secure with the four bolts.

4. Fit a new crankshaft seal. Using special seal replacer tool 18G 1456 and with the lip side leading, drive in the seal up to the shoulder.

ST1517M

Fit water pump and crankshaft pulley

5. Place a new joint washer in position and offer up the water pump. Fit the different length bolts in accordance with the diagram and evenly tighten to the correct torque.

6. Fit the crankshaft pulley and secure with the special washer and bolt. Tighten to the correct torque figure.

FIT OIL PUMP AND SUMP

1. Fit the longer splined end of the drive shaft into the oil pump.

2. Fit the oil pump and drive shaft to t h e crankcase, whilst revolving the shaft as necessary to engage the splines of the skew gear.

3. Using new lock washers, secure the pump to the crankcase tightening the bolts to the correct torque and bend over the lock tabs.

4. If necessary adjust the position of the strainer so that it is parallel to the sump baffle plate.

5 . Clean the sump and crankcase mating faces and fit a new joint washer. Later engines without a joint washer, apply a bead of RTV HYLOSILL 102 black 7 m m

Secure the sump with the twenty-one bolts and spring washers and one nut. Evenly tighten to the correct torque.

FIT CYLINDER HEAD AND ROCKER SHAFT

ASSEMBLY

1. Clean t h e cylinder head and cylinder block mating faces. Position a new cylinder head gasket on the cylinder block with the word ‘Diesel’ uppermost.

2. Lower the cylinder head onto the cylinder block using two long bolts to facilitate accurate positioning of the head.

3. Fit the cylinder head retaining bolts except those also used to secure the rocker shaft and leave finger-tight.

4. Insert the push rods ensuring that the ball end locates properly in the spherical seat in the tappet.

5. Whilst holding the rocker shaft assembly together, lower it into position making sure that the hollow dowels locate properly in the cylinder head. Also ensure that the rocker adjusting screw ball end locate in the push rods.

6. Fit the rocker shaft large retaining bolts and leave finger-tight.

2.50 LITRE DIESEL ENGINE

7. Tighten the cylinder head retaining bolts, evenly, to the correct torque figure in t h e sequence illustrated below.

8. Fit and tighten the rocker shaft, small bolts to the specified torque.

5 . Continue to check and adjust the remaining tappets in the following sequence:

Set N o . 3 tappet with No. 6 valve fully open.

Set No. 5 tappct with No. 4 valve fully open.

Set No. 2 tappct with N o . 7 valve fully open.

Set No. 8 tappet with No. 1 valve fully open.

Set No. 6 tappet with No. 3 valve fully open.

Set No. 4 tappet with No. 5 valve fully open.

Set No. 7 tappet with N o . 2 valve fully open.

Fit the rocker cover

6. Using a new gasket, fit the rocker cover and secure with the dome nuts and washers. Tighten evenly to the correct torque. Do not overtightcn.

ST 880M

ADJUST TAPPET CLEARANCES

1. Tf the crankshaft is rotated with exccssive valve clearances, it is possible that the push rods may become dislodged from tappet seating and fracture the tappct slide. To prevent damage, eliminate all clearance from any loose rockers before turning the crankshaft to adjust thc clearances.

2. Turn the engine over until number eight valve

(counting from front of engine) is fully open.

3. Using a 0,25 mm (0.010 in) feeler gauge check the clearance between the valve tip and rocker pad of number one valve.

4. Adjust the clearance by slackening the lock n u t and turning t h e tappet adjusting screw clockwise to reduce clearance and anti-clockwise to increase clearance. Rechcck the clearance after tightening the lock nut.

FIT THE CLUTCH

1. Clean the flywheel face and place the centrc plate with the side marked ‘Flywheel side’ towards the flywheel.

2. Fit the clutch assembly locating i t over the three dowels and loosely securc with thc six bolts.

3. Centralise the centre plate using special tool RO

605022 or a spare primary shaft and tighten thc six bolts evenly to the correct torque figure. Smear thc splines of thc centrc plate with Molybdenum disulphidc grease, such as Rocol MTS 1000.

-Fit.-

5 ” ,

%-:

S T 7 6 4 M

2.50 LITRE DIESEL ENGINE

112) c

.,.

...

FIT CYLINDER HEAD.OIL FEED

1. Connect the oil feed pipe, for lubrication of the rocker shaft assembly, to thc cylinder head

2. Secure with the two banjo bolts and four join! washers.

FIT

HEATER PLUGS

1. Clean and test the heater plugs as described in the maintenance Section. Fit the heater plugs and tighten to the correct torque. Do not over tighten.

2. Fit the leads, washers and nuts as illustrated, ensuring that cach cable eyelet is fitted vertically downwards to prevent heat from cylinder head damaging the cable insulation.

FIT FUEL LIFT PUMP

1. If the fuel lift was separated from the side cover, fit the pump to t h e cover first using a new joint washer between the pump flange and rear cover, evenly tighten the retaining nuts.

2. Place a new cover plate joint washer in position and fit the cover and pump assembly to the cylinder block.

3. Ensure that the pump actuating lever rides on top of t h e camshaft.

4. Secure t h e cover, evenly tightening the retaining bolts.

FIT OIL FILTER AND ADAPTOR

1. Using a new joint washer fit thc oil filter adaptor.

Ensure that the retaining bolts pass through the two small round holes in the joint washer.

2. Tightcn the two retaining bolts evenly to the correct torque.

ST762M

3 . Smear a little clean enginc oil on the rubber washer of thc new filter, then screw the filter on clockwise until the rubber sealing ring touches the machined

$nap

LULL,

+h-.. +

L I I L L L L I ~ I I L L I I

L U I t

LUIII h., h n - A n - 1 . r uy iiuiiu v r r i y .

Do not overtighten. See Maintenance Operations, section 10. continued

88 la

2.50 LITRE DIESEL ENGINE

FIT VACUUM PUMP

1. Place a new joint washer on the cylinder block face.

2. Fit the D.P.S. pump control bracket.

3. Insert the vacuum pump drive shaft into the skew gear coupling ensuring that the shaft engages properly over the cross pins in the coupling. The hose connection should be towards the front of the engine.

4. Secure the pump and control bracket to the cylinder block with the three socket headed screws.

RENEW 011, TEMPERATURE THERMOSTAT

Used when an oil cooler is fitted.

1. Remove the two bolts and carefully withdraw the thermostat extension housing.

2. Remove t h e ‘0’

3. Withdraw the thermostat.

4. Remove the washer.

5 . Remove the spring.

6. Clean the adaptor housing with lint-free cloth.

7. Fit the spring and washer.

8. Fit a new thermostat with the pin uppermost.

9. Fit the extension housing using a new ‘0’ ring.

Ensure t h a t the pin protruding from thc thermostat locates in the hole in the extension housing.

10. Secure the housing with the two bolts and washers.

5 . Connect the D.P.S. pump control rod to the control bracket lever.

FIT THE FUEL INJECTORS AND PIPES

Fit the injectors

The steel sealing washer fitted below the injector nozzlc is to ensure that combustion does not take place around the nozzle body and cause it to overheat. A washer which has been used more than once, o r an incorrectly fitted washer may cause the nozzle to overheat and result in that cylinder misfiring.

1. Ensure that the new washers are separated from each other and are clean.

2. Use a length of thin welding wire to guide one washer only into each port with the domed side toward the injector as illustrated. Ensure that only one washer is fitted to each port.

2.50 LITRE DIESEL ENGINE 12

3 . Lightly grcasc the copper washer into position o n each injector before fitting to the cylinder head.

4. Fit the injector and evenly tighten the retaining nuts to the correct torque. Uneven or overtightening of the injector nuts could distort the nozzle and cause misfiring when normal running temperature is reached.

Fit the injector pipes

2. Fit t h e injcctor pipes to the injectors and D.P.S. pump. Counting from the front of the engine connect the pipes as follows:

A . To number 1 injector.

B. To number 2 injector.

C. To number 3 injector.

D. To ilurriber 4 injector.

Do not overtighten the union nuts.

FIT THE STARTER MOTOR

1. Fit the starter motor to the flywheel housing and secure with: a) one stud and n u t b) one single bolt c) one nut and bolt.

Evenly tighten to the correct torque. continued

1121

2.50 LITRE DIESEL ENGINE

2. Secure the rear of the motor t o the bracket with two bolts and tighten to the correct torque.

FIT THE AIR INTAKE AND EXHAUST MANIFOLDS

1. Using a new gaskct fit the manifolds and secure with the retaining nuts and clamps. Evenly tighten to the specified torque ligure.

2. Connect the breather hose to the oil filler cap.

ST M

Turbo-charged engines

3. Fit a new gasket to the cylinder head.

4. Fit thc air intake manifold and evenly lighten the bolts to the correct torque.

I I

5. Fit the exhaust manifold and secure with the four socket headed bolts and clamps.

2.50 LITRE DIESEL ENGINE

S T l

ST769M

FIT ALTERNATOR - VOLT

1. Fit adjustment link to front cover.

2. Assemble the alternator to thc engine b r x k c t with the two pivot bolts, distancc piece and washers, leaving the bolts slack.

3. Fit thc adjustment link to the timing cover and attach to alternator with adjusting clamp bolt.

FIT PO WEK STEERING PUMP

1. If removed, fit the jockey pullcy to the spindle.

2. Fit the bracket and jockey pulley assembly to the engine with the three bolts.

3 . Fit the power steering pump to t h e bracket and secure the plate to t h e pump with four bolts.

4. Secure the plate to the bracket with the three bolts.

5 . Fit the drive pulley to the pump with the three bolts.

6. Fit the drive belt.

I .

'. ..

.,.. i...

Adjust belt tension

4. Fit the drive belt and pivot the alternator away from the engine, but do not apply pressure to the stator or slip-ring end bracket o r damage may result. Tighten t h e clamp bolt and with thumb pressure, check t h e belt tension between the fan and alternator pulleys which should be 7 to 9 mm at the mid-point.

5 . When the tension is correct fully tighten the clamp bolts and the pivot nuts and bolts.

1 12 1

2.50 LITRE DIESEL ENGINE

ADJUST POWER STEERING DRIVE BELT

1. Slacken the jockey pulley pinch bolt.

2. Move the jockey pulley to the left or right as necessary to achieve a deflection, by thumb pressure, of 12 mm at the mid-point o f the belt run between the crankshaft and power steering pump pulley.

3. Tighten the pinch bolt.

2.50 LITRE DIESEL ENGINE

,!...

::.....:.:

.. ":, !

....

DIESEL ENGINE MECHANICAL FAULTS

.,,.

...:

. .

SYMPTOM

MAIN BEARING R A T T L E

ENGINE O V E R H E A T I N G

,OW O I L PRESSURE W A R N I N G

-1GHT REMAINS O N , E N G I N E

ZUNNING

POSSIBLE CAUSE

34. Low oil level in sump

35. Low oil pressure

36. Excessive bearing clcarance

37. Burnt-out bearings

38. Loose bearing caps

CURE

Replenish as necessary to high mark on dipstick

Worn bearings. Faulty skew, gcar assembly.

&cylinder engine .

Renew bearings; and o r crankshaft

Renew and investigate reason for failure

Tightcn to correct torque

39. Low coolant level

40. Faulty cooling system

41. Faulty thermostat

42. Cracked cylinder head

43. Defective lubrication system

Chcck for leaks, check expansion tank level

Check fan and belt, pump, radiator fins not

>locked rest and renew, if necessary

Renew

Renew Filter, Check pump, Clean strainer.

:heck oil circulation. Renew oil temperature

:hermos ta t .

44. Thin or diluted oil

45. Low oil level

46. Choked pump strainer

47. Faulty release valve

48. Excessive bearing clearance

40. Oil pressurc switch unscrviccablc

50. Elcctrical fault

51. Rclicf valve plunger sticking

52. Weak rcliefvalvc spring

53. Pump rotors cxcessively worn

54. Excessively worn hearings; main. connecting rod. big cnd. camshaft, etc.

55. Faulty skcw gear assembly. 4-cylinder engines

Drain and rcfill with correct oil and renew filter

Replensih to high mark on dipstick

:lean

Rectify

Renew

:heck circuit

Remove and ascertain cause

Pencw

3verhaul oil pump

4sccrtain which bearings and rectify lheck skew gear bearing. Check plug not leakinf

)r seals in 2.5 diesel engine. Scc engine overhaul

I A T T L E IN LUBRICATION

;YSTEM

JOISY VALVE MECHANISM

, .

AECHANICAL NOISES:

>ow pitch knock

>ow pitch thud ntermittcnt thuds iigh pitch tap

.ight tapping

#lapping

56. Oil pressure relief valve plunger sticking

57. Sticking valves

58. Weak valvc springs

59. Tappet clearance too wide

60. Deterioration of timing belt

Big-end bearing slack o r run

Main bearing slack o r run

Loose flywheel o r excessive crankshaft end-float

Worn gudgeon pins

Exccssive valve clcarancc

Excessive piston clearance -more apparanl when cold

Xemovc and clean

Overhaul cylinder head

V8 CYLINDER ENGINE

DISMANTLE AND OVERHAUL

Remove the engine from the vehicle and clean the exterior. I n the interests of safety and efficient working secure the engine to a recognised engine stand. Drain and discard the sump oil.

Special tools:-

Guide bolts

Torque wrench -

Clutch centralising tool

Gudgeon pin removerheplacer

- -

Adaptor remover/replacer- gudgeon pin.

Spring compressor

Valve guide drift exhaust

Valve cutter handle set -

8.5 Adjustable pilot -MS150

Valve seat cutter -

Distance piece for valve guide -

Drift for guide removal

R0274401

Crankshaft rear seal sleeve

Remove induction manifold

3 . Disconnect miscellaneous pipes and hoses from the induction manifold and the carburetters.

4. Evenly slacken and remove the twclve bolts and l i f t off the induction manifold complete with carburetters.

5 . Wipe away any surplus coolant lying on the manifold gasket and remove the gasket clamp bolts and remove the clamps.

6. Lift off the manifold gasket and seals.

REMOVE ANCILLARY EQUIPMENT

Before commencing, and whilst dismantling, make a careful note of the position of brackets, clips harnesses, pipes, hoses filters and other miscellaneous and non- standard items to facilitate reassembly.

1. Remove the following itemsof equipment:

Starter motor.

Alternator and mounting bracket.

Power stecring pump -

Disconnect spark plug H.T. leads and remove the distributor.

Clutch.

Fan blades, pulley and drive belt.

Remove pulse air rails from cylinder heads.

Dipstick and engine mounting brackets.

Remove water pump

7. Remove the fifteen bolts and withdraw the water pump and joint washer.

Kemove exhaust manifolds

2. Bend back the lock tabs, and remove the eight bolts securing each manifold, and withdraw the manifolds.

V8 CYLINDER ENGINE

I ’

. ., REMOVE AND OVERHAUL ROCKER SHAFTS AND

VALVE GEAR

1. Remove t h e four screws and lift off the rocker covers

2. Remove the four rocker shaft rctaining bolts and lift off t h e assembly complete with baffle plate.

Dismantle rocker shafts

5 . Remove the split pin from one end of the rocker shaft.

4 . Withdraw the following components and retain them in the correct sequence for reassembly:

7 . A plain washcr.

8. A wave washer.

9. Rocker arms.

10. Brackets.

11. Springs.

12. Examine each component for wear, in particular the rockers and shafts. Discard weak or broken springs.

3. Withdraw the pushrods and retain in the sequence removed.

4. Remove the hydraulic tappets and place to one side with their respective pushrods. If a tappet cannot be removed leave i n position until the camshaft is removed.

Inspect tappets and pushrods

13. Hydraulic tappet; inspect inner and outer surfaces of body for blow holes and scoring. Replace hydraulic tappet if body is roughly scored or grooved, or has a blow hole extending through the wall i n a position to permit oil leakage from lower chamber.

14. The prominent wear pattern just above lower end of body should not be considered a defect unless it is definitely grooved or scored. I t is caused by side thrust of t h e cam against thc body while the tappet is moving vertically i n its guide.

15. Inspect the cam contact surface of t h e tappets. Fit new tappets i f the surface is exccssively worn or damaged.

16. A hydraulic tappet body that has been rotating will have a round wear pattern and a non-rotating tappet body will have a square wear pattern with a very slight depression near the centre.

17. Tappets MUST rotate and a circular wear condition is normai. Tappets wiih ihis w e a r paiierri can be refitted provided thcre are no other defects.

18. I n t h e case of a non-rotating tappet, fit it new replacement and check camshaft lobes for wear; also ensure the new tappet rotates freely in the cylinder block. con1 inued

1121

V8 CYLINDER ENGINE

25. Compress the springs, brackets and rockers, and fit a wave washer, plain washer and split pin to the end of the rocker shaft.

26. Locate the oil baffle platc in place over the rockers furthest from the notched end of thc rocker shaft and fit the bolts through the brackets and place the assemblies to one side.

RR750M

19. Fit a new hydraulic tappet if the area where the pushrod contacts is rough or otherwise damaged.

20. Renew any pushrod having a rough or damaged ball end or seat. Also bent rods must be renewed.

REMOVE AND OVERHAUL THE CYLINDER

HEADS

1. Evenly slacken the fourteen cylinder head bolts reversing the tightening order.

2. Before removing the heads mark them relative to the L.H. and R.H. side of the engine.

3. Lift off the cvlinder heads and discard the gasket.

Assemble rocker shafts

21. Fit a split pin to one end of the rocker shaft.

22. Slide a plain washer over the long end of the shaft to abut the split pin.

23. Fit a wave washer to abut the plain washer.

NOTE: Two different rocker arms are used and must be fitted so that the valve ends of the arms slope away from the brackets, as indicated by the dotted lines 'A' on the illustration.

24. Assemble the rocker arms, brackets and springs to the rocker shaft.

Dismantle cylinder heads

4. Remove the spark plugs.

5 . Using the valve spring compressor 276102, or a suitable alternative, remove the valves and springs and retain in sequence for refitting.

ST788M

96 i

6. Clean the combustion chambers with a soft wire brush.

7. Clean the valves.

8. Clean the valve guide bores.

7 w v m -

V8 CYLINDER ENGINE

112)

9. Regrind or fit new valves as necessary.

10. If a valve must be ground to a knife-edge to obtain a true seat, fit a new valve.

11. The correct angle for the valve face is 45 degrees.

12. The correct angle for the seat is 46

'/4 degrees, and t h e seat witness should be towards the outer edge.

Fit new valve guides

14. Lubricate the new valve guide and place in position. Using guide drift 600959 drive the guide into the cylinder head until it protrudes 19 mm

(Xi in) above the valve spring recess in the head.

NOTE: Service valve guides are 0,02 mm (0.001 in) larger on the outside diameter than the original equipment to ensure interference fit.

ST 793M

13. Check the valve guides and fit replacements as necessary. Using the valve guide remover 274401, drive out the old guides from the rocker shaft side of the cylinder head.

Examine and fit new valve seats

15. Check the valve seats for wear, pits and burning and renew the inserts if necessary. continued

V8 CYLINDER ENGINE

16. Remove the old seat inserts by grinding them away until they are thin enough to be cracked and prised out.

17. Heat the cylinder head evenly to approximately 65 degrccs C (1 50 degrees F).

18. Press thc new insert into the recess in the cylinder head.

NOTE: Service valve seat inserts are available in two over-sizes: 0,25 and 0,50 mm (0.010 and 0.020 in) larger on the outside diameter to ensure interference fit.

19. If necessary, cut t h e valve seats to 46

'14 degrees.

20. The nominal seat width is 1,5 mm (0.031 in). If t h e seat exceeds 2,O mm (0.078 in) it should be reduced to the specified width by the use of 20 and

70 degrec cutters.

21. The inlet valve seat diameter, A is 37,03 mm

(1.358 ins) and the exhaust valvc seat is 31,50 mm

(1.240 ins) diametcr.

ST1024M

23. Smear a small quantity of engineers' blue round the valve seat and revolve a properly ground valve against the seat. A continuous fine line should appear round the valve. If there

IS a gap of not more than 12 mm it can be correctcd by lapping.

24. Alternatively, insert a strip of cellophane between t h e valve and seat, hold the valve down by thc stem and slowly pull out the cellophane. I f there is a drag the seal is satisfactory in that spot. Repeat this in at least eight places. Lapping-in will correct a small open spot.

Assemble valves to cylinder head

25. Before fitting the valves and springs the height of each valve above the head must be checked. Insert each valve in turn in its guide and whilst holding the head firmly against the seat, measure the height of the stem above the valve spring seat surface.

This dimension must n o t exceed 47,63 mm

(1.875 ins). If necessary renew the valve or grind the end of the valvc stem.

26. Lubricate the valve stcms and assenible the valves, springs and caps and secure with the collets using valve spring compressor 276102.

NOTE: Seals are fitted to the inlet valves on later engines, but these can also be fitted to early engines if required.

P;;

ST797M

22. Ensure that the cutter blades are correctly fitted to the cutter head with t h e angled end of t h e blade downwards facing t h e work, as illustrated.

Check that the cutter blades are adjusted so that the middle of the blade contacts the area of material to be cut. Use the key provided i n the hand set MS 76. Use light pressure, and remove only the minimum material necessary.

V8 CYLINDER ENGINE

1121

Reclaiming cylinder head threads

Damaged or stripped threads in the cylinder head can be salvaged by fitting Helicoils as follows:

I~Ioles - These threc holes may be drilled 0.3906 in. dia. x 0.937

0.040 in. deep. Tapped with Helicoil Tap

No. 6 CPB or 6CS x 0.875 in. (min.) deep (g UNC 1%D insert).

Holes B - dia. x 0.812

0.040 in. deep. Tapped with Helicoil Tap

No. 6 CBB 0.749 in. (min.) deep

UNC 1MD insert).

Holes C - dia. x 0.937 four holes may be drilled 0.3906 in.

0.040 in. deep. Tapped with Helicoil Tap

No. 6 CPB or 6CS x 0.875 in. (min.) deep ($ insert).

Holes D - in. dia. x 0.675

0.040 in. deep. Tapped with Helicoil Tap

No. 4CPB or 4CS x 0.625 in. (min.) deep ( % UNC

1 KD insert).

Holes E - six holes may be drilled 0.3906 in. dia. x 0.937

0.040 i n . deep. Tapped with Hclicoil Tap

No. 6 CPR or 6CS x 0.875 i n . (min.) deep (i insert).

NOTE: Right-hand cylinder head illustrated.

American projection.

F Exhaust manifold face

G Inlet manifold face

H Front face

I Rear face

J Front of engine

\ I I

/ \

ST 799M

V8 CYLINDER ENGINE

REMOVE AND OVERHAUL FLYWHEEL

1. Remove the retaining bolts and withdraw the flywheel from the crankshaft.

6. Place a chisel immediately above the drilled hole and strike it sharply to split the starter ring gear.

2. Examine the flywheel clutch face for cracks, scores and overheating. If the overall thickness of the flywheel is in excess of the minimum thickness i.e.

39,93 mm (1.572 in) it can be refaced provided that after machining it will not be below the minimum thickness. Remove the three dowels before machining.

3. Examine the ring gear and if worn or the teeth are chipped and broken it can be renewed as follows:

7. Heat the new ring gear uniformly t o between 170 degrees and 175 degrees C (338 degrees to 347 degrees F) but d o not exceed the higher temperature.

8. Place the flywheel, clutch side down, on a flat surface.

9. Locate the heated starter ring gear in position on the flywheel, with the chamfered inner diameter towards the flywheel flange. If the starter ring gear is chamfered both sides, it can be fitted either way round.

10. Press the starter ring gear firmly against the flange until the ring contracts sufficiently to grip the flywheel.

11. Allow the flywheel to cool gradually. Do NOT hasten cooling in any way or distorting may occur.

12. Fit new clutch assembly location dowels to the flywheel.

ST803M

4. Drill a 10 mm (.375 in) diameter hole axially between the root of any tooth and the inner diameter of the starter ring sufficiently deep to weaken the ring. D o NOT allow the drill to enter the flywheel.

5 . Secure the flywheel in a vice fittcd with soft jaws and piace a cioth over the fiywheei to protect rhe operator from flying fragments.

WARNING: Take adequate precautions against flying fragments when splitting the ring gear.

ST804M

100

REMOVE TIMING GEAR COVER AND WATER

PUMP

1. Place an oil drip-tray beneath the timing cover and remove the oil filter element.

2. Remove the crankshaft pulley bolt and special washer and withdraw the pulley.

3. Remove the t w o bolts securing the sump to the bottom of the timing cover.

Renewing timing cover oil seal

S. Remove the seven drive screws and withdraw the mud shield and the oil seal.

6. Position the gear cover with the front face uppermost and the underside supported across t h e oil seal housing bore on a suitable wooden block.

7. Enter the oil seal, lip side leading, into the housing bore.

8. Press in the oil seal until the plain face is 1,s m m

(0.062 in) approximately below thc gear cover face.

9. Fit the mud shield and secure with the screws.

ST805M

4. Remove the remaining timing cover retaining bolts and withdraw the cover complete with oil pump.

REMOVE AND OVERHAUL THE OIL PUMP

1. Remove the bolts from t h e oil pump cover.

2. Withdraw t h e oil pump cover.

3. Lift off the cover gasket.

4. Withdraw the oil pump gears.

101

12 V8 CYLINDER ENGINE

Dismantle pump

5 . Unscrew the plug from the pressure relief valve.

6. Lift off the joint washer for the plug.

7. Withdraw the spring from the relief valve.

8. Withdraw the pressure relief valve.

ST809M

Assemble pump

17. Insert the relief valve spring.

18. Locate the sealing washer on to the relief valve plug.

19. Fit the relief valve plug and tighten to 4,0 to

4,9 kgf m (30 to 35 Ibf ft).

20. Fully pack the oil pump gear housing with petroleum jelly. Use only petroleum jelly; no other grease is suitable.

21. Fit the oil pump gears so that t h e petroleum jelly i s forced into every cavity between the teeth of the gears.

,,-,-..

. ...<.

IMPORTANT: Unless the pump if fully packed with petroleum jelly it may not prime itself when the engine is started.

22. Place a new gasket on the oil pump cover.

23. Locate the oil pump cover in position.

24. Fit the special fixing bolts and tighten alternately and evenly to the correct torque. e::.*

<'j

. .

Examine pump

9. Check the oil pump gears for wear or scores.

10. Fit the oil pump gears and shaft into t h e Front cover.

11, Place a straight-edge across the gears.

12. Check the clcarance betwccn the straight-edge and the front cover. If less than 0,05 mm (0.0018 in), check the front cover gear pocket for wear. REMOVE TIMING CHAIN GEARS AND

CAMSHAFT

1. Remove the retaining bolt and washer a n d withdraw the distributor drive gear and spacer. continucd

13. Chcck the oil pressure relief valve for wear or scores.

14. Check the relief valve spring for wear at the sides or signs of collapse.

15. Clz.!n the gauze filter for the relief valve.

16. Check the fit of the relief valve in its bore. The valve must be an easy slide fit with no perceptible side movement.

102

ST81lM ---'-- e'"-'-

/, ,d.%:h. c.

2. Withdraw the chaln wheels complete with timing chain.

V8 CYLINDER ENGINE

112

6. Measure t h e camshaft journals for overall wear, ovality and taper. The diameters of the five journals are as follows commencing from the front of the shaft.

Number 1 journal 1.786 to 1.785 ins

Number 2 journal 1.750 to 1.755 ins

Number 3 journal 1.726 to 1.725 ins

Number 4 journal 1.696 to 1.695 ins

Number 5 journal 1.666 to 1.665 ins

7. To check the camshaft for bow, rest the two end journals i.e. numbers 1 and 5 on ‘V’ blocks and mount a dial gauge on the centre journal. Rotate t h e shaft and note the reading.

If

the run out is more than 0,05 mm (0.002 in) it should be renewed.

3. Withdraw thc camshaft whilst taking particular carc not to daniagc thc bearings in t h e cylinder block.

REMOVE AND OVERHAUL CONNECTING-RODS

AND PISTONS

1. Withdraw the remaining bolts and remove [he sump.

2. Remove the sump oil strainer.

3. Removc the connccting-rod caps and retain them in sequence for reassembly.

4. Screw the guide bolts 605351 onto the connecting- rods. continued

. ....

...

Examine components

4. Visually examine all parts for wear. Check t h e camshaft bearing journals and cams for wcar, pits, scores and overheating. Should any of these conditions be present the shaft should be renewed.

5. Examine the links and pins of the timing chain for wcar and compare its condition with that of a I.ew chain. Similarly the teeth of t h e chain wheels should be inspected a n d i f necessary the wheels should be renewed.

103

V8 CYLINDER ENGINE

5 . Push the connecting-rod and piston assembly up the cylinder bore and withdraw it from the top.

Retain the connecting-rod and piston assemblies in sequence with their respective caps.

6. Remove the guide bolts 605351 from the connecting-rod. d . Locate the piston adaptor 18G 1150 E with its long spigot inside the bore of the hexagon body. e . Fit the remover/replacer bush of 18G 1150 on the centre screw with the flanged end away from the gudgeon pin. f. Screw the stop-nut about half-way onto the smaller threaded end of the centre screw, leaving a gap ‘A’ of 3 mm (B in) between this nut and the remover/replacer bush. g. Lock the stop-nut securely with the lock screw. h. Check that the remover-replacer bush is correctly positioned in the bore of the piston. i. Push the connecting-rod to the right to expose the end of the gudgeon pin, which must be located in the end of the adaptor ‘d’. j. Screw the large nut up to the thrust race. k. Hold the lock screw and turn the large nut until the gudgeon pin has been withdrawn from the piston. Dismantle the tool. e ypJ continued

Overhaul

NOTE: The connecting-rods, caps and bearing shells must be retained in sets, and in the correct sequence.

Remove the piston rings over the crown of the piston. If the same piston is to be refitted, mark it relative to its connecting-rod to ensure that the original assembly is maintained.

7. Withdraw the gudgeon pin, using tool 18G 1150 as follows: a. Clamp the hexagon body of 18G 1150 in a vice. b. Position the large nut flush with the cnd of the centre scrcw. c. Push the screw forward until the nut contacts the thrust race. d a c b !

ST777M

104

...

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. .

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8. As an alternative to tool 18G 1150, press the gudgeon pin from the piston using an hydraulic press and the components which comprise tool

605350 as follows: a. Place the base of tool 605350 on the bed of an hydraulic press which has a capacity of 8 tons (8 tonnes). b. Fit the guide tube into the bore of the base with its countersunk face uppermost. c. Push the piston to one side so as to expose one end of the gudgeon pin and locate this end i n the guide tube. d . Fit the spigot end of the small diameter mandrel into the gudgeon pin. e. Press out the gudgeon pin, using the hydraulic press.

V8 CYLINDER ENGINE

New pistons

Pistons are available in service standard sizc and in oversizes of 0,25 mm (0.010 in) and 0,50 m m

(0.020 in). Service standard size pistons are supplied 0,0254 mm (0.001 in) oversize. When

..fitting new service standard size pistons to a cylinder block, check for correct piston to bore clearance, honing the bore if necessary. Bottom of piston skirt-bore clearance should be 0,018 to

0,033 mm (0.0007 to 0.0013 in).

NOTE: The temperature of the piston and cylinder block must be the same to ensure accurate measurement. When reboring the cylinder block, the crankshaft main bearing caps must be fitted and tightened to the correct torque.

9. Check the cylinder bore dimension at right angles to the gudgeon pin, 40 to 50 mm

(1'/2 to 2 in) from the top.

Original pistons

Remove the carbon deposits, particularly from the ring grooves.

Examine t h e pistons for signs of damage or excessive wear; refer to 'new pistons' for the

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,I pistons if necessary.

10. Check the piston dimension at right angles to the gudgeon pin, at the bottom of the skirt.

11. T h e piston dimension must be 0,018 to 0,033 m m

(0.0007 to 0.0013 in) smaller than the cylinder.

12. If new piston rings arc to be fitted without reboring, deglaze the cylinder walls with a hone, without incrcasing the bore diameter to provide a cross-hatch finish. continued

105

lz[

V8 CYLINDER ENGINE

13. Check the compression ring gaps in the applicable cylinder, held square to thc bore with the piston.

Gap limits: 0,44 to 0,56 mm (0.017 to 0.022 in).

Use a fine-cut flat file to increase the gap if required. Select a new piston ring if the gap exceeds the limit.

NOTE: Gapping does not apply to oil control rings.

Fit piston rings

17. Fit the expander ring into the bottom groove making sure that the ends butt and do not overlap.

18. Fit two ring rails to the bottom groove, one above and one below the expander ring.

19. Fit the second compression ring with the marking

‘TOP’ uppermost and the chrome compression ring in the top groove, either way round.

ST819M

14. Temporarily fit the compression rings to the piston.

15. The ring marked ‘TOP’ must be fitted with the marking uppermost and into t h e second groove.

The chrome ring is for t h e top groove and can be fitted either way round.

16. Check the compression ring clearance in the piston groove. Clearance limits: 0,Oj to O , ~ O

0.004 in).

ST821M

Examineconnec*ing-rods

20. Check the alignment of the connecting-rod.

21. Check the connecting-rod small end, the gudgeon pin must be a press f i t . cont inucd

106

V8 CYLINDER ENGINE

112

Check crankshaft bearings

22. Locate t h e bearing upper shell into the connecting- rod.

23. Locate the connecting-rod and bearing on to the applicable crankshaft journal, noting that t h e domed shape boss on t h e connecting-rod must face towards the front of the engine on the right-hand bank of cylinders and towards the rear on the left-hand bank.

24. When both connecting-rods are fitted, the bosses will face inwards towards each other.

25. Place a piece of Plastigauge across the centre of the lower half of the crankshaft journal.

26. Locate the bearing lower shell into the connecting- rod cap.

27. Locate the cap and shell on to the connecting-rod.

Note that the rib on the edge of the cap must be the same side as the

- connecting-rod. shape boss

On the

28. Secure the connecting-rod cap, and tighten to the correct torque.

IR/II'ORTANT: The connecting-rods, caps and bearing shells must be retained in sets, and in the correct sequence,

....

29. Do not rotate the crankshaft or connecting-rod while the Plastigauge is in USC.

30. Remove the connecting-rod cap and shell.

31. Using the scalc printed on the Plastigauge packet, measure t h e flattened Plastigauge at its widest point.

32. The graduation that most closely corresponds to the width of the Plastigauge indicates the bearing clearance.

33. The correct bearing clearance with new or overhauled components is 0,013 to 0,06 mm

(0.0006 !e 0.0022. in>.

34. If a bearing has been in service, i t is advisable to fit a new bearing i f t h e clearance exceeds 0,08 mm

(0.003 in).

35. I f a new bearing is being fitted, use selective assembly to obtain the correct clearance.

36. Wipe off the Plastigauge with an oily rag. DO NOT scrape i t off.

Assembling pistons to connecting-rods

37. If an hydraulic press and tool 605350 was used for dismantling, refit cach piston to its connccting-rod as follows: a. Check that the base of tool 605350 and the guide tube are fitted as follows:-

Place the base of tool 605350 on the bed of a n hydraulic press which has a capacity of 8 tons (8 tonnes).

Fit the guide tube into the bore of the base with its countersunk face uppermost. b. Fit the long mandrel inside the guide tube. c. Fit the connccting-rod into the piston with the markings together if the original pair arc being used, t h e n place the piston and connecting-rod assembly over the long mandrel until the gudgeon pin boss rests on thc guidc tube. d . Fit the gudgeon pin into the piston up to the connecting-rod, and the spigot end of the small diameter mandrel into the gudgeon pin. e. Press i n the gudgeon pin until it abuts the shoulder of the long mandrel. continucd

107

V8 CYLINDER ENGINE

38. If tool 18G 1150 was used for dismantling, refit each piston t o its connecting-rod as follows: a . Clamp the hexagon body of 18G 1150 in a vice, with the adaptor 18G 1150 E positioned as in 4d. b. Remove the large nut of 18G 1150 and push the centre screw approximately 50 mm (2 in) into the body until the shoulder is exposed. c. Slide t h e parallel guide sleeve, grooved end last, onto the centre screw and up to the shoulder.

A d . Lubricate t h e gudgeon pin and bores of the connecting-rod and piston with graphited oil

(Acheson’s Colloids ‘Oildag’). Also lubricate the ball race and centre screw of 18G 1150. e. Fit the connecting-rod and the piston together onto the tool with the markings together if the original pair are being used and with the connecting-rod around the sleeve up to the groove. f . Fit the gudgeon pin into t h e piston bore up to the connecting-rod. g. Fit the removerheplacer bush 18G 115013 with its flanged end towards the gudgeon pin. h . Screw the stop-nut onto t h e centre screw and adjust this nut to obtain a 1 mm (& in) end-float

‘A’ on the whole assembly, and lock the nut securely with the screw. i. Slide the assembly back into the hexagon body j. and screw on the large n u t up to the thrust race.

Set the torque wrench 18G 537 to 12 Ibf ft. This ,e:>; represents t h e minimum load for an acceptable interference fit of the gudgeon pin in the con necti ng-rod. k . Using the torque wrench and socket 18G 587 on t h e large nut, and holding the lock screw, pull t h e gudgeon pin in until the flange of the remover-rcplacer bush is 4 m m (0.160 in) ‘B’ from the face of the piston. Under no circumstances must this flange be allowed to contact the piston.

CAUTION: If the torque wrench has not broken throughout the pull, the fit of the gudgeon pin to the connecting-rod is not acceptable and necessitates the renewal of components. The large nut and centre screw of the tool must be kept well-oiled.

39. Remove the tool and check that t h e piston moves freely on the gudgeon pin and that no damage has occurred during pressing. e, e.

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ST778M

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.::.2 REMOVE AND OVERHAUL CRANKSHAFT

1. Remove the main bearing caps and lower bearing shells and retain in sequence. It is important to keep them in pairs and mark them with thc number of the respective journal until it is decided if thc bearing shells are to be rcfitted.

2. Lift out the crankshaft and rear oil seal.

V8 CYLINDER ENGINE

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Inspect and overhaul crankshaft

3 . Rest the crankshaft o n vee-blocks at numbers one and five main bearing journals.

4. Using a dial test indicator, check the run-out at numbers two, thrce and four main bearing journals. The total indicator readings at each journal should not exceed 0,08 m m (0.003 in).

5. While checking t h e run-out at each journal, note the relation of maximum eccentricity on each journal to the others. The maximum on all journals should come at very near the same angular iocation.

6. If the crankshaft fails to meet the foregoing checks it is bent and is unsatisfactory for service.

7. Check each crankshaft journal for ovality. If ovality exceeds 0,040 mm (0.0015 in), a reground or new crankshaft should be fitted. continued

109

112

V8 CYLINDER ENGINE

8. Bearings for the crankshaft main journals and the connecting-rod journals are available in the following undersizes:

0 3 (0.010 in)

0,50 mm (0.020 in)

9. The centre main bearing shell, which controls crankshaft thrust, has the thrust faces increased in thickness when more than 0,25 mm (0.010 in) undersize, as shown o n thc following chart.

RR1793E

Crankshaft dimensions

Crankshaft

G r a d e

Diameter

'12'

Width

'13'

Diameter

'14'

Standard

0,254 u/s

0,508 U/S s8,4oo-s8,413 26,97s-27,020 wwo-sn.812

58,146-58,158 26,97527,026 50,546-50,559

57,892-57,904 27,22927,280 50,292-.50,305

Crankshaft dimensions

Crankshaft

G r a d e

Standard

0.010 u/s

0.020 u/s

Diameter

'12'

2.2992-2.2997

2.2892-2.2897

2.2792-2.2797

Width

'13'

Diamctcr

'14'

I .062-1 .Oh4 2.0000-2.0005

1.062- I .Oh4 1.9900- 1.9905

I .072- I .074 1.9800- 1 .'I805

10. When a crankshaft is to be reground, the thrust faces on either side of the centre main journal must be machined in accordance with the dimensions on the following charts.

Main bearing journal size

Standard

0.25 mm 0.010 in) undersize

0,50 mm t0.020 in) undersize

Thrust face width

Standard

0,25 mm in) ovcrsize

11. For example: If a 0,50 mm (0.020 in) Undersize bcaring is to be fitted, then 0,12 m m (0.005 in) must be machined off each thrust face of thc centre journal, maintaining the correct radius.

Check main bearing clearance

16. Remove the oil seals from the cylinder block and the rear main bearing cap.

17. Locate the upper main bearing shells into the cylinder block. These must be the shells with the oil drilling and oil grooves.

18. Locate the flanged upper main bcaring shell in the centre position.

19. Place the crankshaft in position on the bearings.

Crankshaft dimensions

12. The radius for all journals except the rear main bearing is 1,90 to 2,28 mm (0.075 to 0.090 in).

(0 1 3 0 ;"\

% a & ) .

14. Main bearing journal diameter, sec the following charts.

15. Thrust face width, and connecting-rod journal diameter, see t h e following charts. continued

110

20. Place a piece of Plastigauge across the centre of the crankshaft main bearing journals.

21. Locate the bearing lower shell into the main bearing cap.

22. Fit numbers one to four main bearing caps and shells. Torque: 7,O to 7,6 kgf m (50 to 55 Ibf ft).

23. Fit the rear main bearing cap and shell. Torque:

9,0 to 9,6 kgf m (65 to 70 Ibf ft). Do not allow the crankshaft to be rotated while the Plastigauge is in use.

24. Remove the main bearing caps and shells.

25. Using the scale printed on the Plastigauge packet, measure the flattened Plastigauge at its widest point.

26. The graduation that most closely corresponds to the width of the Plastigauge indicates the bearing clearance.

V8 CYLINDER ENGINE

112

ASSEMBLING ENGINE

27. The correct bearing clearance with new or overhauled components is 0,023 to 0,065 mm

(0.0009 to 0.0025 in).

28. If the correct clearance is not obtained initially, use selective bearing assembly.

29. Wipe off the Plastigauge with an oily rag. Do NOT scrape it off.

30. Maintain the bearing shells and caps in sets and in the correct sequence.

FIT CRANKSHAFT AND MAIN BEARINGS

1. Locate the upper main bearing shells into thc cylinder block; these must be the shells with the oil drilling and oil grooves.

2. Locate the flanged upper main bearing shell in the centre position.

3. Lubricate the crankshaft main bearing journals and bearing shells with clean engine oil and lower the crankshaft into position.

Renew spigot bearing

31. Carefully remove the old bearing.

32. Fit the spigot bearing flush with, or to a maximum of 1,6 m m (0.063 in) below the end face of the crankshaft.

33. Ream the spigot bearing to 19,177

(0.7504

0,025 mm

0.001 in) inside diameter. Ensure all swarf is removed.

I l l

V8 CYLINDER ENGINE

4. Lubricate the lower main bearing shells and fit numbers one to four main bearing caps and shells only, leaving the fixing bolts finger tight at this stage.

5 . Fit the cruciform side seals to the grooves each side of the rear main bearing cap. Do not cut the side seals to length, they must protrude 1,5 mm

(0.062 in) approximately above the bearing cap parting face.

6.

Apply Hylomar PL32M jointing compound to thc rearmost half of the rear main bearing cap parting face or, if preferred, to the equivalent arca on the cylinder block as illustrated.

7. Lubricate the bearing half and bearing cap side seals with clean engine oil.

8. Fit the bearing cap assembly to the engine. Do not tighten the fixings at this stage but ensure that the cap is fully home and squarely seated cylinder block. on the

9. -Tension the cap bolts equally by one-quarter turn approximately, t h e n back off one complete turn on each fixing bolt.

NOTE: The lubricant coating must cover the seal guide outer surface completely to ensure that the oil seal lip is not turned back during assembly.

Position the oil seal, lipped side towards the engine, onto the seal guide. The seal outside diameter must be clean and dry.

12. Push home the oil seal fully and squarely by hand into the recess formed in the cap and block until it abuts against the machined step in the recess.

Withdraw the seal guide.

13. Tighten the main bearing cap bolts to the corrcct torque noting that the bolts for numbers one to four bearings have a different torque to number five bearing cap bolts.

14. Using a feeler gauge or a dial indicator check the crankshaft end-float, 0,lO to 0,20 mm (0.004 to

0.008 in).

ST831M'

CAUTION: Do not handle the seal lip, visually check that it is not damaged and ensure that the outside diameter remains clean and dry.

10. Position the seal guide RO 1014 on the crankshaft flange.

11. Ensure that the oil seal guide and the crankshaft journal are scrupulously clean, then coat the seal guide and oil seal journal with clean engine oil.

CAUTION: D

O not exceed 1,000 engine rev/min when first starting the engine, otherwise the crankshaft rear oil seal will be damaged. c-*

112

,.”

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. FIT CONNECTING-RODS AND PISTONS

1. Locate the applicable crankshaft journal at B.D.C.

2. Place the bearing upper shell - rod.

3. Retain the upper shell by screwing the guide bolts

605351 onto the connecting-rods.

4. insert the connecting-rod and piston assembly into its respective bore, noting that the domed shape boss on the connecting-rod must face towards t h e front of the engine on the right-hand bank of cylinders and towards the rear on the left-hand bank. When both connecting-rods are fitted, the bosses will face inwards towards each other.

V8 CYLINDER ENGINE 112

7. Using a piston ring compressor, locate the piston into the cylinder bore, until the piston crown is just below the cylinder block top face.

8. Pull the connecting rods on to the crankpins using the guide rods.

5. Position the oil control piston rings so that the ring gaps are all at one side, between t h e gudgeon pin and piston thrust face. Spacc t h c gaps in the ring rails approximately 25 m m (1 in) each side of thc expander ring joint.

6 . Position the compression rings so that their gaps are on opposite sides of the piston between the gudgeon pin and piston thrust face.

.. . . ., ST835M

9. Place the bearing lower shell in thc connecting-rod cap.

10. Locate the cap and shell onto t h e connecting-rod, noting that the rib on the edge of the cap must be towards the front of the engine on the right-hand bank of cylinders and towards the rear on the left-hand bank.

11. Check that the connecting-rods move freely sideways on the crankshaft. Tightness indicates insufficient bearing clearance connecting-rod. or a misaligned continued

I 1 3

1121

V8 CYLINDER ENGINE

12. Check the end-float between the connecting-rods on each crankshaft journal. Clearance limits: 0,15 to 0,37 mm (0.006 to 0.014 in).

13. Tighten thc connecting-rod nuts to the correct torque. Fit the oil straincr and joint washer.

3. Temporarily fit the camshaft chain wheel with the marking ‘FRONT’ or ‘F’ outwards.

4. Turn the camshaft until the mark on the camshaft chain wheel is at the six o’clock position, then remove the chain wheel without disturbing thc camshaft.

5. Encircle the chain wheels with the chain keeping the timing marks aligned.

‘ 5

FIT CAMSHAFT TIMING GEARS AND CHAIN

1 . Lubricate the camshaft journals and carefully insert the camshaft into the cylinder block.

6. Engage the chain wheel asscmbly on the camshaft and crankshaft key locations and check that the camshaft key is parallel t o the shaft axis to ensure adequate lubrication of the distributor drive gear.

2. Turn the crankshaft t o bring number one piston to

T.D.C.

114

&$;.A

,‘.

CAUTION: The space between the key and keyway acts as an oilway for lubrication of the drive gear. Ensure that the key is seated to the full depth of the keyway. The overall dimension of shaft and key must not exceed

30,15 mm (1.187 in). Dimension A below.

V8 CYLINDER ENGINE

FIT THE FLYWHEEL

1. Locate the flywheel in position on the crankshaft spigot, with the ring gear towards the engine.

2. Align the flywheel fixing bolt holes which arc off-set to prevent incorrect assembly.

3 . Fit the flywheel fixing bolts and before finally tightening, take up any clearance by rotating the flywheel against the direction of engine rotation.

Tighten the bolts evenly to the correct torque.

-I.

ST841 M

7. Check that the timing marks line-up and fit t h e spacer with the flange to the front.

8. Fit the distributor drive gear ensuring that the annular grooved side is fitted to the rear, that is towards the spacer.

9. Secure the drive gear and camshaft chain wheel assembly with the bolt and washer and tighten to the correct torque.

FIT CYLINDER HEADS

1. Fit new cylinder head gaskets with the word ‘TOP’ uppermost. Do NOT use sealant. continucd

I

RR 1799E

115

V8 CYLINDER ENGINE

2. Locate the cylinder heads on t h e block dowel pins.

3. Clean the threads of t h e cylinder head bolts then coat them with Thrcad Lubricant-Sealant Loctite

572.

FIT TAPPETS, PUSH RODS AND ROCKER

ASSEMBLIES

Fit tappets and push rods

1. Fit the tappets and push rods to their original locations. Ensure that the tappets move freely in their respective bores. Before fitting the tappets immerse them in clean engine oil to reduce tappet noise when the engine is first started after the overhaul.

4. Locate t h e cylinder head bolts in position as illustrated and fit dipstick tube.

Long bolts - 5 .

Medium bolts-2,4,6, 7 , 8 , 9 and 10

Short bolts -

5 . Tighten the cylinder head bolts a little at a time in the scqucnce shown to t h e following figures:

Bolts 1 to 10 65 to 70 Ibf f t (88 to 95 Nm).

Bolts 11 to 1440 to 45 Ibf ft (54 to61 Nm).

6. When all bolts have been tightened, re-check the torque settings.

Fit the rocker assemblies

2. The rocker shafts are handed and must be fitted correctly to align the oilways.

3 . Each rocker shaft is notched at one end and on one side only. The notch must be uppermost and towards the front of the engine o n the right-hand side, and towards the rear on t h e left-hand side. p.

.- continued

Note: Left-hand cylinder head illustrated.

Arrow points to front of vehicle.

116

.,:.+

.- ,

’

4. Fit the rocker shaft assemblies. Ensure that the push-rods engage the rocker cups and that the baffle plates are fitted to the front on the left-hand side, and to the rear on the right-hand side.

Tighten the bolts.

V8 CYLINDER ENGINE

)121

3. Apply ‘Hylomar’ sealing compound SQ32M on the corners of the cylinder head, manifold gasket and manifold, around the water passage joints.

4. Fit the manifold gasket with the word ‘FRONT’ to the front and the open bolt hole at the front R.H. side.

5. Fit the gasket clamps but do not fully tighten the bolts at this stage.

It should be noted that tappet noise can be expected on initial starting-up after an overhaul due to oil drainage from the tappet assemblies or indeed if the vehicle has been standing over a very long period. If excessive noise should be apparent after an overhaul, the engine should be run at approximately 2,500 rev/min for a few minutes (subject to the following caution), when the noise should be eliminated.

CAUTION: Do not exceed 1,000 engine rev/min when first starting the engine, otherwise the crankshaft rear oil seal will be damaged.

FIT THE INDUCTION MANIFOLD

1. Coat both sides of new manifold gasket seals with silicon grease.

2. Locate the seals in position with their ends engaged in the notches formed between the cylinder head and block.

6. Locate the manifold onto the cylinder head.

7. Clean the threads of t h e manifold securing bolts and apply Loctitc 572 to the threads.

8. Fit all the manifold bolts and tighten them a little at a time, evenly, alternate sides working from the centre to each end and finally tighten to the correct torque.

9. Tighten the gasket clamp bolts to the correct torque.

117

V8 CYLINDER ENGINE

FIT THE TIMING COVER AND CRANKSHAFT

PULLEY

1. Place a new timing cover joint washer in position and fit the timing cover locating it on the two dowels.

2. Clean t h e threads of the timing cover securing bolts, then coat them with Thread Lubricant-

Sealant Loctite 572.

3. Fit and evenly tighten the timing cover bolts to the correct torque figure.

4. Fit the crankshaft pulley and tighten the retaining bolt to the correct torque.

5 . Fit timing pointer.

ST850M

W I

FIT THE SUMP

1. Clean t h e sump mating faces and a t the joint between the timing cover and crankcase apply a coating of a universal jointing compound about 13 to 19 mm

(Y2 to

Y4 in) wide in the area illustrated.

ST849M

FIT THE WATER PUMP

1. Lightly grease a new joint washer and place i t in position on the the timing cover.

2. Clean thc threads of t h e four long bolts and smear them with Loctite 572 thread lubricant-sealant.

Locate the water pump i n posiiion.

3 . Locate the alternator adjusting link on the water

Pump.

4. Leave the alternator adjusting link loose and tighten the remaining water pump housing bolts evenly and to t h e correct torque.

118

2. Place the sump gaskct in position, fit the sump and evenly tighten the retaining bolts to the correct torque. Hylosil is used o n later engines instead of a

V8 CYLINDER ENGINE

(12)

.I .... ::

TEST AND FIT THERMOSTAT

1. Remove the two bolts securing the thermostat housing to the induction manifold.

2. Remove the housing gasket.

3. Withdraw t h e thermostat.

ST858M

8. Clean the induction manifold and thermostat housing mating faces.

9. Fit the thermostat with the jiggle pin uppermost at

12 o'clock.

10. Fit the housing using a new gasket, and evenly tighten the two bolts.

ST856M

4. Note the temperature stamped on the thermostat at which it should be fully open.

FIT THE DISTRIBUTOR distributor

- electronic

1. Turn the crankshaft t o bring number one piston to

T.D.C. on the compression stroke (both valvcs closed number one cylinder).

2. Turn distributor drive until rotor arm is approximately 30" anti-clockwise from number one sparking plug lead position on cap.

3. Turn the oil pump and distributor common drive shaft so that the tongue is in the approximate position as illustratcd. continued

ST857M

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Centigrade thermomelcr in a laboratory beaker, or a suitable alternative, half full of water.

6. Heat the water and observe the temperature at which the thermostat opens.

7. If faulty discard the thermostat.

119

1121

V8 CYLINDER ENGINE

4. Fit distributor t o engine and check that centre line of rotor arm is now in line with number one sparking plug lead in cap. Reposition distributor if nccessary. T h e vacuum capsule should be at 90” to the camshaft.

5 . If distributor does not seat correctly in front cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine.

6. Fit clamp and bolt leaving both loose at this stage.

FIT ROCKER COVERS

1. Remove all traces of old gasket on t h e covers and cylinder heads.

2. Clean and dry the gasket mounting surface, using

Bostik cleaner 6001.

3 . Apply Bostik 1775 impact adhesive to the seal face and the gasket, using a brush to ensure an even film. Allow the adhesive to bccome touch-dry, approximately fifteen minutes.

NOTE: The gasket fits one way round only and must be fitted accurately first time; any subsequent movement would destroy the bond.

4. Place one end of the gasket into the cover recess with the edge firmly against the recess wall; at the same time hold thc remainder of thc gasket clear; then work around the covcr, pressing the gaskct into place ensuring that the outer edgc firmly abuts the recess wall.

7. Rotate distributor anti-clockwise until contact points just start to open.

8. Secure distributor in this position by tightening clamp bolt.

9. Fit the distributor cap and spark plugs and connect the H.T. leads in accordancc with the illustration below.

NOTE: The above distributor setting is to enable the engine to be run so that the correct setting given in ‘Engine Tuning data’ can be achieved once the engine is refitted to the vehicle.

5 . Allow the cover to stand for thirty minutes before fitting i t to t h e engine.

6. Secure t h e rocker covers to t h e enginc with the four screws. Short screws -

- out board.

120

V8 CYLINDER ENGINE

.;$.,

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FIT ENGINE OIL FILTER

1 . Clean oil pump mating face with filter.

2. Smear clean engine oil on the rubber washer of the new filter.

3. Fill the filter with new oil as far as possible, noting the angle at which t h e filter is to be fitted.

4. Screw on the filter until the sealing ring touches the oil pump cover face, then tighten it a further half turn by hand only. Do not overtighten.

FIT THE FAN PULLEY, VISCOUS COUPLING AND

FAN

1. Secure the fan to the viscous coupling with the four bolts and tighten evenly.

2. If removed, fit the pulley to hub assembly adaptor and secure with the four nuts.

3. Screw the viscous coupling onto the adaptor thread by inserting a tommy bar in the hole in the pulley to restrain it while tightening the coupling.

4. Fit the fan and any other drive belts.

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FIT THE CLUTCH

1. Clean the flywheel and clutch assembly pressure plate.

2. Fit the centre plate and t h e clutch assembly and loosely secure to thc flywheel with the retaining bolts.

3. Insert centralising tool 18G 79 or a slave primary shaft and finally tighten the clutch assembly retaining bolts in a diagonal sequence, to the correct torque.

4. Smear the centre plate splines with Rocol MV3 or

Rocol MTS 1000 grease.

FIT THE ALTERNATOR

1. Offer up the alternator to the mounting bracket and locate the pivot nuts and bolts noting that the fan guard is attached to the front nut and bolts.

2. Slacken the alternator adjustment bracket and attach alternator bracket. Note that the fan guard is attached to the adjustment bracket bolt.

3. Fit and tension the fan belt as follows:

Pivot the alternator away from the engine but in doing so, d o not apply any pressure to the slip-ring end bracket. Tighten the pivot nuts and bolts and adjustment bolt. The tension is correct when, with thumb pressure, the belt deflection is approximately 8 m m

(A in) for non-air condition engines, 4 mm (& in) for air condition engines, oitP-..n+n- --A the crankshaft pu!!ey.

Finally, tighten the fixings and connect the wiring plug to t h e alternator. continued

ST854M

121

V8 CYLINDER ENGINE

ST855M

FIT EXHAUST MANIFOLD AND AIR RAILS

1. Ensure that the mating surfaces of the cylinder head and exhaust manifold are clean and smooth and coat the faces with ‘Foliac J 166’ or ‘Moly Paul’ anti-seize compound. ‘Foiiac J 166’ is manufactured by Rocol Ltd., Rocol House,

Swillington, Leeds, England.

‘Moly Paul’ is manufactured by K . S . Paul Products

Ltd., Nobel Road, London N18.

2. Place the manifold in position on the cylinder head and fit the securing bolts, lockplates and plain washers. The plain washers are fitted between the manifold and lockplates. Evenly tighten the manifold bolts to the correct torque figure and bend over the lock tabs.

3. Fit pulse-air rails to cylinder heads.

FIT THE CARBURETTERS

If removed, fit the carburetters t o the induction manifold, using new joint washers in the correct sequence as illustrated according to the engine serial number. See Section 19 for S.U. Carburetters.

Illustration A from serial number 1400001A Non- detoxed.

1. Fit the liner.

2. Fit the two joint washers.

3. In between the washers fit the insulator.

Illustration B from serial number 15G00001A detoxed.

4. Fit the three joint washers.

5. Fit the saw toothed deflector.

6. Fit the insulator.

122

MISCELLANEOUS AND NON-STANDARD ITEMS

Fit any other items of equipment and miscellaneous hoses, pipes, filters, clips and brackets to the positions noted during dismantling.

‘K .,/

FAULT DIAGNOSIS 12 r

...

.+:<.

. ::.;

PETROL ENGINE

FAULT DIAGNOSIS

SYMPTOM

E N G I N E FAILS TO S T A R T

E N G I N E STALLS

LACK OF POWER

1. Incorrect starting procedure

2. Starter motor speed too

3. Faulty ignition system slow

4. Water o r dirt in fuel system

5 . Carburetter(s) flooding

6 . Defective fucl pump

7. Defective starter motor

8. Starter pinion not engaging

1. Low idling speed

2. Faulty sparking plugs

3. Faulty coil o r condenser

4. Faulty distributor points

5. Incorrect mixture

6. Foreign mattcr in fuel system

1. Poor compression

2. Badly seating valves

3. Faulty exhaust silencer

4. Incorrect ignition timing

5 . Leaks or restriction in fucl system

6. Faulty sparking plugs

7. Excessive carbon deposit

8. Brakes binding

9. Faulty coil, condenscr or battery

CIJRE

See owners handbook

Check battery and connections

Check each component in system

Flush out system with clean fuel

Check float chaniber needle valve

Remove, overhaul or renew

Overhaul or rcnew

Remove starter motor and overhaul

Adjust carburetter(s)

Clean and test; renew if necessary

Renew

Rectify or renew

Adjust carburettcr(s)

Investigate source of foreign matter and cleai as necessary

If the compression is appreciably less then thc corrcct figure, the piston rings or valves are faulty. Low pressure i n adjoining cylinders indicates a faulty cylinder head gasket

Overhaul cylinder head(s)

Renew

Check and adjust using electronic equipment

Check through system

Clean, test and renew, if necessary

Decarbonize

Adjust brakes or overhaul

Determine which component and renew

ENGINE RUNS E R R A T I C A L L Y

ZNGINE STARTS, B U T STOPS

'MMEDIATELY

ZNGINE F A I L S T O I D L E

XNGINE MISFIRES O N A C C E L E R A T I O N

ZNGlNE KNOCKS

ZNGlNE BACKFIRES

I. Faulty clcctrical connections

2. Defectivc sparking plugs

3. Low battcry charge

4. Dcfectivc distributor

5 . Foreign matter i n fuel system

6. Faulty fuel pump

7. Sticking valves

8. Defective valve springs

9 . Incorrect ignition timing

10. Worn valve guides o r valves

1 I , Faulty cylinder head gaskets

12. Damaged exhaust system

13. Vacuum pipes, disconnected at inlet manifold. distributor o r gearbox

I . Faulty electrical connections

2. Foreign matter in fuel system

3. Faulty fuel pump

4. Low fuel level in tank

1. Incorrect carburetter setting

2. Faulty fuel pump

3. Sticking valves

4 . Faulty cylinder head gasket(s)

I . Distributor points incorrectly set

2. Faulty coil o r condenser

3. Faulty sparking plugs

4. Faulty carburetter(s)

5. Vacuum pipes disconnected at inlct manifold

1. Ignition timing advanced

2. Excessive carbon deposit

3. Incorrect carburetter setting

4 . Unsuitable fuel

5 . Worn pistons o r bearings

6. Distributor advance mechanism faulty

7 . Defective sparking p!ugs

1. Ignition defect

2. Carburetter defect

3. Sticking valve

4. Weak valve springs

5 . Badly seating valves

6. Excessively worn valve stems and guides

7. Excessive carbon deposit

X. Incorrect sparking plug gap

9. Air lcak in induction o r exhaust systems

,heck sccurity o f all ignition connections

,lean, test and renew if necessary

Recharge battery and test for condition

Remove and overhaul

3ctermine source of dirt, and clcan systcm

Pcmove and overhaul o r rcncw

3verhaul cylinder head s

3vcrhaul cylinder headis]

?heck timing with electronic equipment, if

)ossible

3verhaul cylinder hcad(s) i e n e w gaskets

Xectify o r renew iefit pipes

-heck HT leads for cracked insulation; check ow tension circuit l e t e r m i n e source of matter and clean system i e m o v e , overhaul o r renew icplcnish

Xdjust as necessary i e m o v e , overhaul o r renew

3verhaul cylinder head(s) k n e w

;et to correct dwell angle tenew

,lean, tcst o r renew h e r h a u l

-heck all vacuum connectlons. Renew faulty

Jipes idjust using elcctronic equipmcnt lecarbonise idjust idjust ignition timing to suit octane rating h e r h a u l engine

{enew capsule and re-check

:!can, :es: and iciicw if nccessary

:heck all ignition components and timing t h e r h a u l carhuretter(s)

Overhaul cylinder head

:lean and resef k n e w faulty gaskets or components

123

124

FAULT DIAGNOSIS

SYMPTOM

B U R N E D VALVES

NOISY V A L V E M E C H A N I S M

POSSIBLE CAUSE

1 . Sticking valves

2. Weak valve springs

3. Excessive deposit on valve seats

4. Distorted valves

5. Excessive mileage between overhauls

I . Excessive oil in sump, causing air bubbles in hydraulic tappets V8 engine

2. Worn o r scored parts in valve operating mechanism

3. Valves and seats cut down excessively, raising end of valve stem, 1,27 mm

(0.050 in) above normal position

4. Sticking valves

5. Weak valve springs

6 . Worn timing chain o r chain wheels

Overhaul cylinder head

Drain and refill t o correct level on dipstick

Replace faulty parts

Grind off end of valve stem o r replace parts

V8 engine only

]

Overhaul cylinder head

Renew worn parts

NOISE F R O M H Y D R A U L I C TAPPETS

V8 E N G I N E ONLY

Rapping noise only when engine is started

2. Intermittent rapping noise

3. Noise on idle and low speed

4. General noise at all speeds

5. Loud noise at normal operating temperature only

MAIN B E A R I N G R A T T L E

L O W 011. PRESSURE

WARNING L I G H T R E M A I N S

O N , E N G I N E R U N N I N G

R A T T L E IN L U B R I C A T I O N SYSTEM

E N G I N E O V E R H E A T I N G

I. Oil too heavy for prevailing temperature

Excessive varnish in tappet

2 .

Leakage at check ball

Excessive leakdown

High oil level in sump

Leakage at check ball

Worn tappet body

Worn camshaft

5. Excessive leak-down rate o r scored lifter plunger

I . Low oil level in sump

2. Low oil pressure

3. Excessive bearing clearance

4. Burnt-out bearings

5. Loose bearing caps

1 . Thin or diluted oil

2. Low oil level

3 . Choked pump strainer

4. Faulty release valve

5 . Excessive bearing clearance

6 . Oil pressure switch unserviceable

7. Electrical fault

8. Relief valve plunger sticking

9. Weak relief valve spring

10. Pump rotors excessively worn

I . Excessively wom bearings: main, connecting rod, big e n d , camshaft. etc

12. Faulty skcw gear asscmbly, 4-cylinder engines

1. Oil pressure rclief valve plunger sticking

I . Low coolant level

2. Faulty cooling system

3. Faulty thcrmostat d . Tncorrcct timing

5. Defcctive lubrication system

Drain and refill with correct grade

Replace tappet

Drain and refill t o correct level on dipstick

Replace tappet

Replacc camshaft

Replace tappet

Replenish as ncccssary to high mark on dipstick

Worn bearings. Faulty skew, gear asscmbly.

4-cylinder enginc

Renew bearings; grind crankshaft NOT diesel

Renew and investigate reason for failure

Tighten to correct torque

Drain and refill with correct oil and renew filter

Replcnish to high mark on dipstick

Clean

Rectify

Renew

Check circuit

Remove and ascertain cause

Renew

Overhaul oil pump

Ascertain which bearings and rectify

Check skew gear bearing. Chcck plug not leaking or seals in 2.5 diesel engine. See

Zngine overhaul

Remove and clean

Chcck for leaks. Check expansion tank level

Check fan and belt, pump, radiator fins

?ot blocked rest and renew, if necessary

Check and adjust using electronic equipmcnt

Renew filter. Check pump. Clean strainer.

:heck oil circulation

M E C H A N I C A L NOISES

Medium low pitch knock

Low pitch thud

High pitch tap

Intermittent thuds

Continual tapping

Continual slapping

3ig-end bearing slack o r run dain bearing slack or run

Worn gudgeon pins aose tly wheel or excessive crankshaft end-float

Zxcessive valve clearance .- N O T V8

'iston clearance excessive. - more apparent vhen sngine cold may disappear when engine

101

FAULT DIAGNOSIS

DIESEL ENGINE MECHANICAL

FAULTS

SYMPTOM

MAIN B E A R I N G R A T T L E

ENGINE O V E R H E A T I N G

POSSIBLE CAUSE

34. Low oil level i n sump

35. Low oil pressure

36. Exccssive bearing clearance

37. Burnt-out bearings

38. Loose bearing caps

39.

40.

Low coolant level

Faulty cooling system

41. Faulty thermostat

42. Cracked cylinder head

43. Defcctive lubrication system

LOW O I L P R E S S U R E W A R N I N G L I G H T

REMAINS O N , E N G I N E R U N N I N G

44. Thin o r diluted

45. Low oil level oil

46. Choked pump strainer

47. Faulty release valve

48. Excessive bearing clearancc

49. Oil pressure switch unserviceable

50. Electrical I'ault

51. Relicf valvc plunger sticking

S2. Weak rclicfvalvc sprin:

53.

54.

Pump rotors excessively worn

Excessively worn bearings) main, connecting rod. big end, camshaft, c t c

55. Faulty skew gear assembly, 4-cylinder engines

_ _ _

XATTLE IN L U B R I C A T I O N SYSI'EM

JOISY VALVE MECHANISM

56. Oil pressure relief valve plunger sticking

57.

5X.

Sticking valves

Weak valve springs

59. Tappet clearance too wide

60. Worn timing chain or chain wheels vlECHANICAL NOISES:

,ow pitch knock

,ow pitch thud ntermittent thuds

4igh pitch tap

.ight tapping

;lapping

Big-end bearing slack o r run

Main bearing slack

01' run

Loose flywhecl o r excessive crankshaft end-float

Worn gudgeon pins

Excessive valve clearance

Excessive piston clearance whcn cold

DIESEL ENGINE

CURE

Replenish as necessary to high mark on dipstick

Worn bearings. Faulty skew, gear assembly.

4-cylinder engine

Renew hearings; and or crankshaft

Renew and investigate rcason for failure

Tighten to correct torque

Check for Icaks, check expansion tank level

Check fan and belt, pump, radiator fins not blocked

Test and renew, if necessary

Renew

Renew Filter, Check pump. Clean strainer.

Check oil circulation

Drain and refill with correct oil and renew filter

Replenish to high mark on dipstick

Clean

Rectify

Renew

Check circuit

Remove and ascertain cause

Renew

Overhaul oil p u m p

Ascertain which bearings and rectify

Check skew gear hcaring. Check plug not leaking or seals i n 2.5 diesel engine. See engine overhaul

Remove and clean

~ ~

Ovcrhaul cyliiidcr head

FAULT DIAGNOSIS DPA AND DI'S PUMPS - and 2.5 litre diesel engines

SYMPTOM

DIFFICULT S T A R T I N G

POSSIIILE CAUSE

1. Lack of fucl

2. Stop solenoid faulty

3. Wrong starting procedure

4. Air in fucl system

5 . Fucl inlct restriction

6. Fuel contamination

7. Low cranking spccd

8. Starting aid ineffective

9. Injcction timing incorrect

10. Timing bclt slipped

1 I. B x k Icakagc restricted

12. Fucl circuit incorrect

13. Engine condition

14. Fuel atomisation

15. Fucl tank blockage

16. H P pipe lcakirig

17. Injection pump defective intcrnally

CHECK

Fuel level in tank

Audible opcration when switched

- electrical supply, replace solenoid

Starting procedure correct -Throttle c!osed and heater plugs in operation

All joints and unions arc tight

Filter not chocked and feed pipes clear

Diesel fucl being used. not pctrol, free of water. dirt, ice. wax.

Battery, startcr, cable connections. Correct engine lubricating oil

Correct functioning of heater plugs

Punip to engine timing using timing tool

Belt condillon and tcnsion. Pump rotor not

I seized

Tank return clear, flow from cam box valve when cranking. Replace pump if blocked

Inlet and back leak pipes correct way round.

Banjo bolts of correct type for pump injector scating

Cylinder compression, valve timing and clearances. Air filter not choked

Injectors; correct type, opening pressure. spray condition

Tank vent and outlet unrestricted

H P pipe joint tightncss

If all other relevant checks salisfiictory, replace pump

125 continued

126

1211

FAULT DIAGNOSIS

SYMPTOM

I R R E G U L A R IDLE

INSUFFICIENT MAXIMUM S P E E D

ERRATIC RUNNING O R S U R G I N G

EXCESSIVE SMOKE

EXCESSIVE NOISE

LACK O F POWF,R

EXCESSIVE FUEL C O N S U M P T l O N

3TALLING

3LOW ENGINE DIE DOWN

ZNGINE WILL N O T S H U T O F F

SXCESSNE KNOCKING (DETONATION)

POSSIBLE CAUSE

Any of the following items: 4 , 5 , 6 , 9 , 1 1 , 12,13,

14, 16, 17. Plus:

18. HP pipe restriction

19. Idlingspeed incorrect

20. Anti-stall setting incorrect

21. Manual idle advance faulty

22. Accelerator linkage faulty

23. Engine vibration

24. Injection pump loose

CHECK

HP pipes not kinked or bore reduced at nipples

Idling speed given in ‘engine tuning data’

Recovery from acceleration, engine warm

(Reset idling and anti-stall)

Cable and lever operation satisfactory

Lever tight on pump reaches stop screws, linkage wear, adjustment

Engine mountings tight and effective

Tightness of pump drive mounting bolts and rear support bracket nut and bolt

Any of items 4,5, 17,22. Plus the following:

25. Max. speed setting incorrect

26. Vehicle brakes binding

Any of items I , 2 , 4 , 5 , 9 , 1 2 , 1 3 , 14,155, 16,

17, 18.27.23.24.

Anv of items 6 . 9 . 13. 14 and 17

Any of items 9 , 1 4 , 2 4 , 2 3 . Plus the following:

27. Cambox pressure IOW Pressure with gauge a t control cover vent screw. Replace pump if pressure too low

A n y o f i t c m s 4 , 5 , 6 , 9 , 11, 12, 13, 14.IS.16,

1 8 , 2 2 , 2 4 , 2 5 , 2 6 . Plus the following:

28. Exhaust system defective

29. L.P. leakage

A n y o f i t e m s 9 , 1 3 , 14, 16.17, 19,26.

Any of the following items; 4,5, 6 , 9 , 1 1 , 13,

1 7 , 1 9 , 2 0 . 2 1 .

Any of the following items; 1 7 , 2 0 , 2 2

Either of the following two items: 2 and 17.

Plus:

30. Stop solenoid valve leaking

Seal intact. Engine maximum speed in

‘Engine tuning data’ adjust

Brake freedom, all wheels in turn and transmission brake

System is unrestricted

Feed and return pipes, filter and tank for leak

Engine stops when supply lead removed.

Replace solenoid if faulty

Items 8 , 9 , 13 or any of the following:

31, Injectors sticking

32. Lack coolant in radiator

33. Lack of oil in engine

Injectors individually

- overhaul’

Cooling system and expansion tank level.

Radiator fins not blocked

Oil level o n dipstick

~ x 2

OVERHAUL FUEL LIFT PUMP

DISMANTLE

1. Remove the sediment bowl, where fitted, and collect the filter gauze and sealing washer.

2. Mark the upper and lower halves of pump casing to ensure correct alignment on reassembly.

3. Remove top cover fixing screws, and while pressing diaphragm tab against pump body, lift top cover clear.

P ETROL FU EL SYSTEM

119

5 . Turn, whilst pressing down the metal part of the diaphragm through 90" in either direction and withdraw the diaphragm and spring.

6 . Unstake the oil seal housing and lever-out the oil scal and retainer.

ST1096M

4. If necessary remove the valves by cutting away the retaining stakes with a scraper. Warm the top cover, note the position of the valves and withdraw them from the cover.

7. Using a small chisel, rcmovc thc staking from the rocker arm retainers.

8. Withdraw the retainers.

9. Withdraw the rocker arm.

10. Withdraw the rocker arm pin and washers.

11. Dctach the operating link.

12. Withdraw thc rocker arm spring.

,. ,.

..*

. . . .

. .

. 2 .

13. It is unlikely that t h e hand priming mechanism will ever require replacement, but i t can be removed by filing the hexagon each side of the operating lever and springing the hand lever clear, withdraw the cork washers and hand rocker.

PETROL FUEL SYSTEM

Inspect

14. Clean all parts in paraffin (Kerosene) and examine for wear and renew as necessary including all gaskets .

Sediment bowl filter disc must be free of damage 15. and fit tightly around inlet neck of upper casing.

16. Renew diaphragm assembly if any sign of hardening, cracking or porosity is present.

17. Only very slight wear should be tolerated at the rocker arm contact face, pivot pin, operating link and diaphragm pull rod slots.

18. Springs should be renewed ensuring that the correct type are used.

19. Test valves for air tightness, by suction.

20. Check upper and lower casing flanges for distortion, using a straight edge.

Assemble

21. Fit the rocker arm spring.

22. Fit t h e operating link.

23. Fit the rocker arm pin and washers.

24. Fit the rocker arm assembly to the pump body and secure with the retainers and stake.

25. Fit the oil seal and retainer and secure by staking.

29. Fit the filter gauze and sealing ring on pumps with a sediment bowl and fit the bowl and secure with the retaining clip. Ensure that the bowl and seal are located squarely. Do not overtighten securing n u t to prevent cracking the bowl.

Test fuel pump

30. Immerse pump in a bath of paraffin and operate rocker arm several times to flush.

31. Hold the pump clear of the bath and continue to operate the rocker arm until the pump is empty, then place a finger over the inlet port and operate rocker arm several times. A distinct suction should be heard when the finger is removed from the inlet port, denoting that a reasonable degree of suction has been developed.

32. Place a finger over the outlet port and again operate the rocker arm. Air pressure should be felt for two to three seconds after rocker movement has

&:>. ceased. Build up the air pressure in the pump

c-."

again, and with the finger held firmly over the outlet, submcrge the pump completely in the paraffin bath, then observe t h c joint face edges for signs of air leakage.

26. To refit the diaphragm assembly, hold the pump body with the diaphragm rcturn spring in position, and the rocker arm held outwards. Position the diaphragm over the spring with t h e flattened end of the pull rod in line with the slot in the opcrating link. Push t h e diaphragm inwards and turn to lock.

27. Fit the inlet and outlet valves and secure by

28. staking.

Place top cover assembly in position, aligning the marks made before dismantling. Fit securing screws, but do not tighten at this stage; using hand priming lever, fully depress diaphragm and fully tighten securing screws.

The diaphragm

0 1 r edges should be approximately flush

1 pump joint faces when

the outer edge of the

OVERHAUL ELECTRICAL FUEL PUMP

NOTE: The electrical components of the pump are sealed and cannot be repaired.

DISMANTLE

1. Remove pump from the vehicle, and clean outside of pump before dismantling.

2. Release the end-cover from the bayonet fixing.

3. Remove the following items: a) filter and seal b) magnet c) gasket

--.

" _

": _-

Pump piston assembly

4. Carefully prise out the retaining clip.

5 . The following parts will then bc released: a) plain washer b) rubber seal c) one-way valve

6.

Withdraw t h e piston return spring with the piston.

If t h e piston remains in the pump tube, hold the pump body vertically (in the fitted position) and tap t h e closed end until the piston is released from its magnetic hold and drops out.

NOTE: The piston is fitted with a one-way valve which should not be disturbed. 4'

0 -J con t

I n ued

PETROL FUEL SYSTEM

1191 f -;

. .

7. Remove the short rebound spring.

8. Clean all components in paraffin.

9. Immerse pump body i n petrol and use air-line inside pump tube.

I la

ST 1015M ‘d.

--. s

CARBURETTER FOUR CYLINDER ENGINE

OVERHAUL

DESCRIPTION

The twin bored 32 - 34 DMTL Weber carburetter is a fixed choke instrument with a staggered throttle opening. The carburetter is divided, operationally, into two sections namely the primary and secondary carburetters with 32 mm and 34 mm bores respectively.

The delayed throttle opening occurs in the secondary carburetter.

The primary carburetter, which incorporates fuel and air jets for idling, is used for starting, and normal running, up to approximately two thirds throttle opening. Shortly before this stage the secondary carburetter butterfly will begin to open and become increasingly more involved as the throttle is opened further. To ensure a smooth transition during the various stages of throttle opening both sections of the carburetter contain progression fuel and air jets and ports.

To prevent fuel vaporisation and air locks i n the system fuel is continuously pumped back to the fuel tank from the carburetter float chamber. The top of thc float chamber is so designed that fuel is drawn off from thc main stream via the needle valve as dictated by the fuel level in the chamber.

NOTE: The fuel filter assembly, instructions 2 and

3, can be carried out with the pump on the vehicle.

ASSEMBLE

Pump piston assembly

10. Fit the short rebound spring.

11. Fit the return spring over the opposite end of the piston.

12. Slide the piston assembly into the pump body.

13. Fit the following items: a) plain washer b) rubber seal c) one-way valve

14. Secure t h e assembly with the spring clip.

Fuel filter assembly

15. Fit the filter and seal.

16. Fit the magnet.

17. Fit the end cover with a new gasket.

18. Fit pump to vehicle and ensure that the earth connection lead and its mounting point is clean.

DISMANTLE

1. Remove the carburetter.

2. Disconnect the fast idle cam assembly.

3. Disconnect the chokc link.

4. Disconnect the pull-down lever and linkage.

5. Remove the top cover from t h e carburetter body.

6. Withdraw the float pivot and detach the float.

7. Remove the needle valve attached to the float tag.

8. Remove znd discard the gasket from the top cover.

9. Withdraw t h e needle valve housing.

10. Remove the fuel filter plug and filter.

11. Remove the pull-down capsule.

12. Remove the fuel cut-off solenoid and valve.

13. Withdraw both ‘primary’ and ‘secondary’ idle jct holders noting their positions for ease of reassem bl y.

14. Withdraw both ‘primary’ and ‘secondary’ main jet assemblies, comprising main jet, emulsion tube and air correction jets.

15. Lift out the pump jet.

16. Remove the accelerator pump cover, diaphragm, gasket and spring.

17. Detach the economy pump assembly, comprising cover, spring and diaphragm.

18. Remove the idle mixture control screw. When the adjustment is tamper-proofed, the tamper- proofing cap must be removed to expose the screw. continued

P 19-49 5.47

ST 535 M

21.30

PETR OL FUEL SYSTEM

119 I

,,;.

. .

, ,

)I.

...

19. Mark-up for reassembly purposes and remove the choke butterfly followed by the choke spindle and linkage.

20. Prior to removal, mark each throttle butterfly.

21. Remove the throttle linkage, springs and washers, noting their sequential positions to aid rcassembly.

22. If required remove the primary and sccondary throttle butterflies (after marking-up) followed by the respective spindles.

. ,

. .,:

Inspection and cleaning

23. When cleaning fuel passages, DO NOT use metal tools which could cause dimensional changes in the drillings or jets. Cleaning should be effected using clean fuel, and, where necessary, a moisture free air blast.

24. If the joint faces on the emulsion block, top cover or carburetter body show any signs of distortion or the edges are burred, these faces may be reclaimed by flatting, using fine grade abrasive cloth and a surface plate. Examine the faces for deep scores which would lead to leakage taking place when assembled.

25. New gaskcts and seals should be used throughout the carburetter rebuild. A complete set of gaskets is available for replacement purposes.

26. Examine the throttle spindle bushes for wcar, if oval or badly worn, replace the carburetter body.

27. Examinc the idle mixture volume screw for wear or damage, replace as required.

35. Fit the pump jet with a new '0' ring into the carburetter body.

36. Reassemble the primary jet to the jet holder and fit to the carburetter body.

37. Fit the secondary main and air correction jets to the secondary emulsion tube, locate and secure assembly to the carburetter body.

38. Assemble the secondary jet to the jet holder and fit assembly to the carburetter body.

39. Reassemble the primary main and air correction jets to t h e emulsion tube; and fit assembly to the carburetter body.

40. Fit the fuel filter and filter plug to the top cover.

41. Fit the needle valve seating and washer.

42. Place a new gasket into position.

43. Fit the needle valve into t h e needle valve seating.

44. Position the float tag in the needle valve wire loop.

Align the float carrier with the pin holes and float carrier flange lugs. Sccure the float carrier with the hinge pin.

45. With the needle valve on its seating and the float carrier tag resting against the necdle valve

(ensuring that neither the valve plunger n o r the valve ball are depressed) measurc the distance between the casing and thc front cdge of the float.

46. The dimension required is 7 mm (0.27 in). Any adjustment must be made by bending thc float carrier tag. Adjustments must NOT be made by bending the float carrier arms. continued

. " . .

Reassembly

28. If previously dismantlcd, insert the primary and sccondary throttle spindles into their respective positions.

29. Locate the primary and secondary throttle butterflies on to their respective spindles and loosely retain with t h e special screws. Operate each buttcrfly to centralise it on each spindle and secure the screws and lock them by peening.

30. Refit the throttle spindle assembly to thc carburetter ensuring the pin on the free lever locates in the slot on t h e primary shaft plate, ensuring that the first spring is located on the spacer, whilst the second spring is engaged on the

31. free lever.

Fit the accelerator pump assembly comprising spring, gasket, diaphragm, spring and pump cover.

32. Refit t h e economy pump assembly comprising diaphragm, spring and pump cover.

33. Replace the fuel cut-off valve and solenoid.

34. Fit the idle mixture control screw and carefully turn until fully home, then turn the screw 1 '/r to 2 turns in the reverse direction to serve as an initial setting.

ST567 M

7mm

0.27in

1191

P ETROL F UEL S YSTEM

47. Fit and secure the top cover assembly evenly, to the carburetter body.

48. Fit the choke spindle into its housing.

49. Locate the choke buttcrfly on the spindle and loosely retain with the two special screws. Operate the butterfly to centralise it on the spindle, then secure the screws and lock them by preening.

50. Refit t h e pull-down capsule, cable retaining bracket, spacer and fixings.

51. Fit the pull-down lever engaging the pivot with the pull-down capsule arm. Secure lever assembly with washer and circlip.

52. Fit the float idle cam ensuring the spring is engaged correctly to the cam.

53. Refit the choke link to t h e choke spindle, securing with a new split pin. Engage the opposite end of the choke link to the idle cam.

7. Push the mixture control fully in and confirm that flap ‘B’ is open, that is in the vertical position. n

FOUR

CYLINDER ENGINE CARBURETTER

TUNE AND ADJUST

1. Before attempting any carburetter adjustments ensure that cylinder compressions, valve clearances, spark plug gaps and ignition timing are satisfactory.

Check also that there is no air leakage into the inlet system through the inlet manifold and carburetter gaskets and brake servo hose connections.

Throttle cable

2. Check that the throttle pedal, cable and linkage

3. operate smoothly.

Remove the elbow from the top of the carburetter.

4. If necessary adjust the pedal stop bolt so :hat no strain is exerted on the throttle cable. Depress thc throttle pedal and check that both the butterflies are fully open, then adjust the pedal stop bolt so that it touches t h e floor, without strain on t h e cable and tighten the locknut

5 . Ensure that when the throttle pedal is released both butterflies are closed completely.

Mixture control (cold start)

6. Pull the mixture control cable fully out and chcck that lever ‘A’ is against its stop and the choke flap

‘B’ is fully closed. If necessary adjust the inner cable clamp ‘C’ to achieve this condition.

Fast idle adjustment p?

8. Pull the mixture control out until the dimension =-# between the crank in the vertical rod ‘D’ and the underside of the carburetter top cover, without compressing the spring ‘F‘ 12,5 mm (0.5 in).

Adjust the fast idle screw ‘E’ so that it just makes contact with the fast idle cam.

ST 1094M

P ETROL FU EL SYSTEM 19

;$ji;!

..”

“I

Idle adjustment

NOTE: The idle mixture adjustment screw provides mixture variation at idle speed only. Above idle speed the mixture is determined by fixed size jets.

9. Start the engine and run until the normal operating temperature is attained.

10. Turn the throttle butterfly adjustment screw to obtain an idle speed of 600 to 700 r.p.m.

11. Turn the idle mixture adjustment screw clockwise or anti-clockwise by one-quarter turn increments to obtain the highest engine r.p.m. When this has been achieved, re-adjust, if necessary, the butterfly adjustment screw to maintain the 600 to 700 r.p.m. idle speed.

12. Fit the air intake elbow to the carburetter top.

V8 ENGINE ZENITH

OVERHAUL

- CARBURETTER

DISMANTLE

Remove the piston assembly

1. Remove the carburetters from the engine.

2. Release the four screws and withdraw the top cover and spring.

3 . Withdraw the air valve, shaft and diaphragm assembly .

4. Remove the metering needle retained by a locking screw.

5 . Release the four screws and separate the diaphragm from the air valve.

Remove the float chamber

6. Release the six screws and remove the float chamber and joint washer.

7. Release the float assembly and spindle from the two clips.

8. Unscrew the needle valve and washer from carburetter body.

Dismantle carburetter body

9. Make location marks, as illustrated, to assist correct asscmbly, on the throttlc buttcrfly, spindlc and carburetter body.

10. Right-hand carburetter Release the two screws and remove the butterfly and withdraw thc spindlc.

ST1095M

...

.....

.:.:,

1..

, .

ST1119M

1 1. Left-hand carburetter Remove the iefi-iiand iever assembly. Release the two screws, remove the butterfly and withdraw the spindle.

12. Left-hand carburetter Release the two retaining screws and shake-proof washers and remove the cold start assembly and joint washers. continued

I19 I

PETROL F U EL S Y S TEM

2 ,

. .

‘

L-

E1 e m

-U

C m

3 e x

- m

0 v) h rc

W v

;

-0

0 v)

2 x

- m

.- m

0 9

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O”.k .k t - b Q

PETROL F U EL SYS TEM

1191

13. Dismantle the cold start assembly but D O

N O T remove the discs from the spindle.

14. If necessary, dismantle the throttle spindle lever assemblies from both carburctters.

Slow-running adjustment screws

D o not attempt to remove these screws or break the tamper-proof seals. See Cautionary note under ‘Tune and Adjust’.

Remove temperature compensator

15. Release the two screws and withdraw the temperature compensator unit complete.

16. Remove t h e large and small rubber washers.

CLEANING AND INSPECTION

Cleaning

17. When clcaning fuel passages d o not use metal tools

(files, scrapers, drills etc.) which could cause dimensional changes i n t h e drillings or jets.

Cleaning of all components should be effected using clean fuel and, where necessary, a moisture- free air blast.

Joint washers and seals

18. New gaskets and seals should be used throughout carburetter rebuild. A complete sct of gaskets is available for replacement purposes.

Inspect metering needle; it is machined to very close limits and should be handled with care.

Examine for wear, bend and twist; renew if necessary.

19. Examine the faces for deep scores which would lead to leakage taking place when assembled.

Diaphragm

20. Examine the diaphragm for deterioration, damage and punctures. Do not use any cleaning chemicals on the diaphragm only clean lint free rag.

Float assembly

21. Examine the two plastic floats and check for punctures and damage.

22. Check t h e spindle and retaining clips for wear.

23. Inspect the needle valve assembly for wear. Renew the valve if there is any tendency for the needle to stick.

Cold start assembly

24. Examine all the cold start components for wear and corrosion and the machined faces for scores. continued

1191

P ETROL FUEL SYSTEM

ASSEMBLE CARBURETTERS

Cold start

25. Place the spring on the cold start spindle.

26. Fit the spring retaining clip.

27. Check that t h e discs slide easily on the spindle.

28. Place the cold start spindle on the starter face.

29. Place t h e starter cover in position.

30. Fit the return spring over the spindle.

31. Rotate the spindle until the oval port in the end

32. disc is aligned with the oval port in the starter face.

Fit the cold start lever.

33. Engage the return spring over the lug on the starter cover and the back of t h e cold start lever.

34. Place the cold start gasket onto the carburetter body.

35. Fit ;he cold start assembly to the carburetter body, and check for ease of operation.

ST1116M

STl120M

Throttle spindle, R.H. carburetter

45. Place return spring over threaded end of the spindle.

46. Fit the throttle stop and fast idle lever.

47. Fit the bushed washer, bush outwards.

48. Fit the throttle lever on t h e bushed washer.

49. Fit the plain washer.

50. Fit the tab washer.

5 1 . Fit the throttle adjust,ment lever.

52. Secure the assembly with the nut and lock with a tab.

53. Fit thc throttle butterfly as described in instruction

39 and anchor the return spring as illustrated. See note before instruction 39. continued

Throttle spindle, L.H. carburetter

36. Place the return spring over either end spindle. of the

37. Fit the throttle stop and fast idle lever and secure with spacers, tab washer and nut.

38. Insert t h e throttle spindle from the cold start side of the carburetter body and fit the throttle return spring on the fast idle adjustment lug. Tension the spring half a turn.

NOTE: Slacken the idle adjustment screw clear of lever to facilitate centralisation of the butterfly.

39. Fit the throttle butterfly, maintaining t h e previously marked alignment. Leave the retaining screws loose. Actuate the throttle several times to centralize the butterfly, then tighten t h e retaining screws and lock by peening ends.

40. E: the thr=tt!e !eve: tc the spind!e at the ~ p i ; c ~ : t e end.

41. Place the spacer on the spindle.

42. Place the tab washer o n the spindle.

43. Fit t h e sleeve nut, sleeve end last, and engage the tab washer.

44. Fit t h e throttle adjusting lever.

ST1121 M

51 Y.& s5"1:

P ETROL FUEL SYSTEM

119

. ..

Float chamber assembly

54. Fit the needle valve and new washer.

55. Locate t h e spindle in the float arm and fit the assembly into the retaining clips.

56. Invert the carburetter so that the needle is on its seating and thc float tab is contacting the needle.

Measure the dimension A between the carburetter gasket face and the highest point on the floats. The correct measurement should be 17 to 18 mm (0.67 to 0.71 in). Adjust by bending the float tab. This dimension must be the same for both floats. The float carrier tab must be maintained at right angles to the needle in the closed position.

57. Fit the float chamber and new gasket and evenly tighten the retaining screws.

----

ST7 1 17M

ST1123M

Air valve and diaphragm

58. Fit the diaphragm to the air valve with the inncr tag locating in the air valvc recess.

59. Fit the diaphragm retaining ring and secure with t h e four screws.

60. Fit the metering needle into the air v2!ve and secure with the locking screw.

61. Insert the air valve and needle into t h e carburetter and locate t h e diaphragm outer tag into the recess in the carburetter body.

62. Fit the spring and top cover and secure with the four screws.

63. Fit the damper.

Temperature compensator

64. Clean the carburetter and compensator mating faces.

65. Fit a new inner and outer rubber washer and securc the temperature compensator with thc two screws and shake-proof washers.

Fast idle adjustment

66. Slacken the fast idle adjusting screw.

67. Hold the cold start cam lever in the maximum position.

68. Adjust thc fast idle adjusting screw against the cam lever until there is 0,61 to 0,66 m m (0.024 to

0.026 in) gap between t h e top edge of the throttle butterfly and t h e carburetter barrel wall. Use feeler gauges or a 0,65 mm diameter (No. 72) drill to measure the gap.

69. Secure the locknut on the fast idle adjusting screw without disturbing the adjustment.

I 19 I

PETROL FUEL S YSTEM

V8 ENGINE ZENITH CARBURETTERS

TUNE AND ADJUST

Tamper-proofing

These carburctters may be externally identified by a tamper-proof sealing tube fitted around the slow running adjustment screw.

The purpose of these carburetters is to more stringently control the air fuel mixture entering the engine combustion chambers and, in consequence, the exhaust gas emissions leaving t h e engine.

For this reason the only readily accessible external adjustment is to the throttle settings for idle and fast idle speed and, for the former setting will require the use of a special tool to prevent breaking the tamper- proof seals.

Slow running (idle) adjustment

1. Check that the throttle control between the pedal and the carburetters is free and has no tendency to stick.

2. Check the throttle cable setting with the throttle pedal in the released position. The throttle linkage must not have commenced movement, but commences with the minimum depression of the pedal.

3 . Run the engine until it attains normal operating temperature; that is, thermostat open.

4. Remove t h e air cleaner elbows.

5. Slacken the screws securing the throttle adjusting levers on both carburetters to allow independent adjustment.

; $,; r

CAUTION: Unauthorised breaking of tamper-proofing devices, adjustment of carburetter settings or the fitting of incorrectly related parts may render the vehicle user liable to legal penalties according to local territory legislation.

Whenever adjustments are made to the settings of tamper-proof or emission specification carburetters an approved type CO meter must be used to ensure that the final exhaust gas analysis meets with local territory requirements.

Emission Specifications

All carburetters fitted to the Land-Rover conform at the time of manufacture to particular territory requirements in respect of exhaust and evaporative emissions control. However, in some cases changes to the basic carburetters may have been necessary to achieve this.

Service tools:

605330 -

MS80 -

MS86 or B25243 - Tamper-proofed throttle adjustment tool

6. Start the engine and check the idle speed using a reliable proprietary tachometer.

7 If necessary, adjust the slow running screw to give the correct idle speed, see 'Engine tuning data'. If a tamper-proof sleeve is fitted over this screw the slow running speed can only be adjusted using special tool MS86 or B25243. $3,

.._

-r

The service tool 605330 carburetter balancer must be used to adjust the carburetters. Primarily, this instrument is for balancing the air-flow through the carburetters, but it also gives a good indication of the mixture setting. Investigation has shown that incorrect mixture setting causes either stalling of the engine or a considerable drop in engine rev/min if the balancer is fitted when the mixture is too rich or a considerable increase in r v t

(anin when used wit;] tule mixture setting too weak. B r \ ) r e balancing the carburetters it is most important therefore that the following procedure be carried out:

12 continued

4:.;.:<.i

Mixture setting and balance carburetters

“ U l V

. _

8. Remove the piston damper plug, and using special tool MS80 adjust the mixture. Locate the outer sleeve of the tool to engage a machined slot to prcvent the air valve twisting. Turn the inner tool clockwise to enrich the mixture and anti-clockwise to weaken it. After every adjustment the tool should be removed from the carburetter to allow engine to stabilise. Run engine at 2000 rev/min to aid stabilisation.

9. When t h e mixture is correctly adjusted, the engine speed will remain constant or may fall slowly a small amount as the air valve is lifted.

P E T ROL FUEL S Y ST EM

119

17. Remove balancer. With the mixture setting and carburetter balance correctly adjusted the difference in engine rev/min with the tool 605330 on o r off will be negligible, approximately plus or minus 25 r e v h i n .

T ,.

...

ST1127M

I...

...

10. Check, and if necessary, zero the gauge on balancing tool 605330.

...;

-1:

.. 5

11. Place balancer on the carburetter adaptors, cnsuring that there are no air leaks. If the engine stalls or decreases considerably in speed, thc mixture is too rich. If t h e engine speed increases, the mixture is too weak.

12. If necessary, remove balancer and re-adjust the mixture, then refit the tool.

13. Check balancer gauge reading.

14. I f the gauge pointer is in the ‘zero’ sector, no adjustment is required.

15. If the gauge pointer moves to t h e right, decrease the air-flow through the left-hand carburetter by unscrewing the s!ew ruxnixg screw

G r increase the air-flow through the right-hand Carburetter by turning clockwise the slow running screw. Reverse the procedure if the pointer moves to the left.

16. If the engine idle speed (slow running) rises too high or drops too low during balancing adjust to the correct idle speed, whilst maintaining the gauge pointer in the zero sector.

Check CO level

Use a proprietary non-dispersive infra-red exhaust gas analyser.

18. Insert the probe of the analyser as far as possible into the exhaust tail pipe, start t h e engine and allow a one to one and a half minute stabilisation period.

19. Check that the correct idle speed (slow running) is maintained and observe the C O reading against that given in the data section. If necessary re-adjust the mixturc setting to achieve the correct C O level.

ST 1102M

PETROL FUEL SYSTEM

Adjust throttle linkage

20. On the left-hand carburetter, place a 0,15 m m

(0.006 in) feeler between the underside of the roller on the countershaft lever and the throttle lever.

21. Apply pressurc to t h e throttle lever to hold the feeler.

22. Tighten the screw to secure the throttle adjusting lever, then withdraw the feelcr.

Fast idle adjustment

26. The fast idle adjustment is pre-set on the left-hand carburetter and should not normally require adjustment. If adjustment is required, the correct procedure is to remove the left-hand carburetter and carry out instructions 66 - 69 under carburetter overhaul. Alternatively the fast idle can be approximately set by pulling the choke cable until the mark on the cam is in-line with t h e head of the adjusting screw. Slacken the locknut and adjust the screw against the cam until the correct idle speed is achieved see ‘Engine tuning data’. Tighten the locknut.

23. On the right hand carburettcr, place a 0,15 m m

(0.006 in) feeler between the left leg of the fork on the adjusting lever and the pin o n the throttle lever.

24. Apply light pressure t o the linkage to hold thc feeler.

25. Tighten the screw to secure the throttle adjusting lever, then withdraw thc fcclcr.

ST1

27. Fit t h e air cleaner elbows.

28. Remove the piston damper plug on both carburetters and replenish t h e damper reservoir with S.A.E.20 oil to within 12 mm (0.5 in) from thc top of thc tube and refit damper plug.

STl130M

PETROL FUEL SYSTEM

1191

;: CARBURETTER OVERHAUL

;.’‘

Right hand

- -

.. .

DISMANTLE

1. Remove the carburetters from the engine and clean the exteriors with a suitable solvent.

2. Remove the two nuts and spring washers and withdraw the air intake adaptor and joint washer.

3. Unscrew and remove the piston damper assembly and drain the oil.

4. Remove the three screws and lift-off the suction chamber complete with piston and spring.

5. Remove the spring clip from the top of t h e piston rod and withdraw the piston and spring.

6. Unscrew the fuel metering needle guide locking screw. If the needle cannot be removed from the piston with the fingers, hold the needle as close to the piston as possible, in a soft jawed vice and with

- a sharp pull withdraw the needle, guide and spring assembly.

7. Remove the four screws and withdraw the float chamber cover plate and scaling ring.

8. Remove the jet adjusting lever retaining screw and spring.

9. Withdraw the jet complete with the bi-metal lever and seperate the lever from the jet.

10. Unscrew and remove the float pivot spindle and plain washer, and remove the float.

11. Lift-out the needle valve.

12. Unscrew and remove the needle valve and filter.

13. Unscrew and remove thc jet bearing nut.

14. Invert the carburetter body to allow the jet bearing to fall out. If the bearing sticks, carefully tap it out from t h e bridge side.

15. Remove the piston guide peg.

16. Remove t h e suction chamber-to-body sealing ring.

17. Unscrew and remove the mixture adjusting screw and seal. Use thin nosed pliers to finally withdraw the screw.

18. Bend-back t h e cam lever n u t lock tabs and remove the nut and lock washer.

19. Remove the cam lever and spring.

20. Remove the end seal cover and seal.

21. Remove t h e two screws and withdraw the cold start valve body and seal together with the valve spindle.

Also collect the paper joint washer.

22. Note t h e position of the throttle levers and return spring.

23. Bend-back the lock washer tabs and remove the throttle lever nut.

24. Remove the lock washer, bush washer and throttle actuating lever.

25. Re!eise the thro!t!e retErn spring and remmve the throttle adjusting leaver from the throttle butterfly spindle and remove the return spring.

26. Hold the butterfly closed and mark the relationship of the butterfly to the carburetter flange.

27. Remove the butterfly two retaining screws and withdraw the butterfly from the spindle.

28. Withdraw the throttle butterfly spindle from the carburetter body together with the two seals.

29. Clean all components with petrol or de-natured alcohol ready for inspection. Do not use abrasives for the removal of stains or deposits.

INSPECTION

30. Examine the throttle spindle and bearings for excessive axial clearance.

31. Check the float needle and seating for wear and the float for punctures and renew if necessary.

32. Check the condition of all rubber seals, ‘0’ and joint washers and renew if necessary. The float cover plate seal must be renewed.

33. Examine the carburetter body for cracks and damage.

34. Ensure that the inside of the suction chamber is clean and fit the piston into the chamber without the spring. Hold t h e assembly horizontally and spin the piston. The piston should spin freely in the suction chamber without any tendency to stick.

35. Inspect the metering needle for wear, scores and distortion. Check also that it has the correct designation number -

Section 05.

36. Examine the bi-metal jet lever for cracks.

37. Check all springs for cracks and distortion.

ASSEMBLE

Fit throttle butterfly

38. Fit the throttle spindle to t h e carburetter body and insert the throttle disc into the spindle in its original position. Secure the disc with new screws and ensure that before tightening the throttle disc is correctly positioned and closes properly. Splay the split ends of the screws to prevent turning.

39. Fit new seals to both ends of t h e throttle spindle ensuring that they are fitted the correct way round.

Fit cold start assembly

40. Fit a new ‘0’ t h e valve spindle to the valve body.

43 4.0

ST1873M

41. Fit a new paper j o i n t washer to the valve noting that the half-moon cut-out in the washer is clearance for the top retaining screw. continued

PETROL FUEL SYSTEM

42. Fit the starter assembly to the carburetter body and secure with the two screws.

43. Fit the end seal and cover.

44. Fit the return spring.

45. Fit the cam lever and tension the spring. Fit a new lock washer and secure with the nut and bend the tabs over a convenient flat.

46. Adjust the coils of the spring, if necessary, to prevent coil binding.

CT?374M

KEY TO S.U. CARHURETTER COMPONENTS

Piston damper.

Spring clip.

Suction chamber.

4. Piston.

5. Piston spring.

6. Suction chamber retaining screws -3 off.

7. Needle retaining screw.

8. Needle bias spring.

9. Needle guide.

10. Needle.

11. Suction chamber sealing ring.

12. Throttle adjusting scrcw and scal.

13. Piston key and retaining screw.

14. Mixture adjusting screw and seal.

15. Carburetter body.

16. Throttle butterfly and retaining screws.

17. Throttle spindle.

18. Throttle spindle scals -

19. Float chamber.

20.

21.

Float chamber cover and retaining SCI'CWS.

22.

23.

Float chamber cover seal.

Jet asscm bl y .

Jet bearing.

24 l e t bearing n u t

25.

26.

Bi-metal jet lever.

Jet retaining and adjusting screw and spring.

27. Float needle.

28.

29.

Float needle seat.

Float needle seat filter.

30. Float

31. Float pivot spindle.

32. Cold start and cam lever assembly.

33. Throttle adjusting lever and lost motion assembly.

34. Throttle actuating lever.

35. Bush washer.

36. Throttle lever assembly retaining nut and lock washer. continued f-.

-..-.

... ...

...I

-=LA#

;; .

PETROL FUEL S YSTEM 19

PETROL FUEL SYSTEM

Fit throttle lever assembly

47. Fit the return spring so that the longest leg rests against the throttle adjusting screw housing.

48. Fit the throttle adjusting lever and lost motion assembly and tension the return spring.

49. Fit the throttle actuating lever.

50. Fit the bush washer and lock washer.

51. Fit and tighten the special nut and bend the lock tabs over a convcnient flat.

Fit jet and float assembly

52. Fit the jet bearing, long end towards the float.

53. Fit the jet bearing nut.

54. Clean or renew the filter and fit the float needle seat.

55. Fit the needle valve, spring loaded pin uppermost.

56. Fit the float and secure with the pivot pin.

57. Hold the carburetter in the inverted position so that the needle valve is closed by the weight of the float only. Check using a straight edge that t h e point o n the float, arrowed on the illustration, is

1.0 t o 1.5 mm (0.04 to 0.062 in) below the level of the float chamber face? dimension ‘A’.

58. Adjust the float position by carefully bending the brass pad until the correct dimension is achieved.

After adjustment, check that the float pivots freely about the spindle. T

ST1876M

I continued

._ e.;;.!!,{: 59. Assemble the jet to the bi-metal jet lever and

, ensure that the jet head moves freely in t h e cut-out.

60. Fit the jet and bi-metal jet lever to the carburetter and secure with the spring loaded jet retaining screw.

61. Fit the mixture adjustingscrew.

PETROL FUEL SYSTEM

Fit piston and suction chamber

64. Fit the needle, spring and guide assembly to the piston ensuring that the etched arrow head on the needle locating guide is aligned between the piston transfer holes, as illustrated.

65. Secure and ensure that when t h e screw is tightened the guide is flush with the piston and that the scrcw locates in the guide slot.

. . . .. ,

62. Adjust the mixture screw until the jet is flush with the carburetter bridge, then turn the scrcw a further three and one half turns clockwise.

63. Using a new sealing ring. f i i the float chamber cover, noting that it can only be fitted one way.

Secure with the four screws and spring washers and evenly tighten.

ST1879M

66. Fit the piston key to the carburetter body using a new screw. Tighten thc scrcw and splay the end.

67. Fit a new suction chamber sealing ring to the groove in the carburetter body.

68. T

O prevent the piston spring being 'wound-up' during assembly, tcmporarily fit the piston and suction chamber less thc spring to the body, and pencil mark the relationship of t h e chamber to the body. Remove the suction chamber and fit the spring to the piston. Hold the suction chamber above t h e spring and piston, align the pencil marks and lower the chamber over the spring and piston, taking care not to rotate the suction chamber.

Secure the chamber to the body with the three scrcws, tightening evenly and check that the piston moves freely.

69. Hold the piston at the top of its stroke and fit the spring clip.

70. Fit t h e piston damper.

71. Using a n e w joint washer, fit the air intake adaptor and secure with t h c two nuts and spring washers.

72. Fit the carburetters to the inlet manifold ensuring that the joint washers, dcflector and insulator are fitted in the sequence illustrated. The insulator must be fitted with the arrow hcad uppermost and pointing inwards towards the manifold. Secure with the four nuts and spring washers and tighten evenly to the correct torque.

A . Joint washer.

B. Deflector-teeth pointing inwards.

C . Joint washer.

D . Insulator.

E. Joint washer. continued

PETROL FUEL SYSTEM

ST1880M

73. Connect the linkages and top-up the carburetter dampers with a recommended oil to the top of the hollow piston rod.

74. Tune and adjust the carburetters. be repeated as often as required. It is important that the above cycle is adhered to, otherwise overheating may result and settings may be incorrect. The piston dampers must always be kept topped-up with the correct grade of oil.

Before any attempt is made to check settings a thorough check should be carried out to ensure that the throttle linkage between the pedal and carburetters is free and has n o tendency to stick. Ensure that the choke control lever is pushed fully down.

NOTE: References to left and right hand are as from the drivers seat.

TAMPER -PROOFING

To comply with E.C.E. regulations the idle speed and mixture adjusting screws must be tamper following any adjustments. A red blanking plug; Part number

- must be fitted into the mixture screw resess and a red cap; Part number JZX 1197 fitted over the idle adjustment screw (throttle adjustment screw). continued

ST1914M

TUNE AND ADJUST

Special tools:

Carburetter balancer 605330 or B89

Non-dispersive infra-red exhaust gas anaiyscr

General Requirements Prior to Tuning Carburetters.

Accurate engine speed is essential during carburetter tuning, therefore the distributor pick up air gap and ignition timing must be checked together with the vacuum advance system.

Whenever possible the ambient air temperature of the tuning environment should be between 15" to 26°C (60" to 80°F). When checking engine speed, use an independent and accurate tachometer.

Idling adjustments should be carried out on a fully warmed up engine, that is, at least 5 minutes after the thermostat has opened. This should be followed by a run of one minute duration at an engine speed of approximately 2,500 r e v h i n before further adjustments or checks are carried out. This cycle may

,,.

...

PETROL FUEL SYSTEM

TUNE AND ADdUST

The following instructions apply to both carburetters unless otherwise stated.

Before commencing the following instructions, remove the air cleaner, air intake elbows, mixture adjustment screw plug and mixture screw cap.

CARDURETTERBALANCE

Using balancer 605330

1. Disconnect the interconnecting link between the two carburetters. Fit the balancer t o the carburetter intakes and ensure that there are no air leaks, i f necessary, zero the gauge with the adjustment screw.

2. Start the engine, and if necessary allow i t t o reach normal operating temperature. If the nccdle moves to the right, decrease t h e air flow through the left hand carburetter by unscrewing the idle screw.

Alternatively, increase the air flow through the right hand carburetter by screwing down the idle screw. Reverse the procedure if the pointer moves to the left. Reconnect the carburetter inter- connecting link.

Using balancer B89

3. Disconnect the inter-connecting throttle link between the two carburetters.

4. Back-off t h e idle adjusting screw on each carburetttcr, clear of the throttlc Icver.

5. 'Turn each throttle adjusting screw so that i t touches the throttle lever. then turn the screws by equal amounts to achieve an approximate idle speed o f 700 to 800 rev/min.

6. Press the balancer firmly over the carburetter intake. Press or withdraw the control on the side of the balancer to adjust the meter needle reading to approximately half scale, and note the reading. con t I n ued

PETROL FUEL SYSTEM

7. Without altering the position of the balancer control, place the balancer on the second carburetter intake ahd adjust the idle screw as necessary to achicve the same reading.

8. Alternatively, adjust and check the balance of both carburetters until an idle speed of 700 to

800 rev/min is obtained.

9. Reconnect the throttle inter-connecting link, and again check the idle spced and balance.

Mixture setting

10. Ensure that the engine is still at normal operating temperature.

11. Mark t h e relationship of the suction chamber to the carburetter body, remove the retaining screws and lift off the suction chamber complete with pistons.

12. To achieve a datum setting for the mixture screw, turn it anti-clockwise until the jct is level with t h e carburetter bridge. Check by placing a straight edge across the bridge and adjust as necessary so that the jet just touches the straight edge.

13. Refit the suction chamber and piston, evcnly tighten the retaining screws. Check that the piston moves freely without sticking. Top-up the piston damper.

14. Turn the mixture adjustment screw three and one half turns clockwise.

15. Insert the probe of an infra-red exhaust gas analyser as far as possible up the exhaust pipe, start the engine and allow a one and one half minute stabilisation period.

16. Adjust the mixture screw on both carburetters by equal amounts, rich or weak to achieve a CO reading of 0.5 to 2.5%.

17. If after approximately two minutes the CO level is not satisfactory run the engine at 2000 rev/min for one minute to stabilise the cquipment, continue the setting procedure until a stablc CO reading of 0.5 to 2.5% at an idle speed of 700-800 rev/min is obtained.

ST1915M idle speed aiid :iiikage adjustmen?

18. Check that the engine is at normal operating temperature.

19. Slacken the nut, at the left hand carburetter securing the inter-connecting link ball to the throttle cam lever. r-';

/ continued

n.,

....

:::e:.,:-.:

...

,,,

:zsr

20. Disconnect the inter-connecting link between the carburetters at the left hand carburetter.

21. At the right hand carburetter, release the lock nut and slacken off the lost motion adjustment screw, until it is well clear

of

the spring loaded pad.

22. 'If necessary adjust the idle screw to maintain the correct idle speed. Check the CO level and carburetter balance, adjust if required.

23. Re-connect t h e inter-connecting link to the left hand carburetter.

24. Hold the right hand throttle lever against the idle screw stop and adjust the lost motion screw until contact is made with the spring loaded pad, tighten the lock nut.

25. Check the idle speed and balance. Adjust the lost motion screw to restore balance if necessary.

26. Ensuring that the roller is firmly seated in the lower corner of the cam lever, tighten the nut which

* secures the inter-connecting link ball to the cam lever.

Fast idle adjustment

27. Pull out the cold start control (choke) until the scribed line on the left hand fast idle cam is in-line with the centre of the fast idle screw head.

28. Check that the scribed line on the right hand fast idle cam is similarly in-line with the fast idle screw head. If there is mis-alignment, slacken the fast idle cam link rod screw at the right hand carburetter and move the cam until the scribed line coincides with the centre of the screw head. Tighten the cam rod screw.

29. Turn the fast idle screw clockwise, on each carburetter, until just clear of the cam.

30. Turn the fast idle screw of the leading (left-hand) carburetter down (clockwise) until a slight change in engine speed is noted.

31. Similarly turn t h e fast idle screw of the second carburetter (right-hand) down until a further slight change of engine speed is noted.

32. Adjust the fast idle screws of both carburetters by equal amounts to achieve a fast idle speed of 1100 to 1150 redmin.

33. Tighten the fast idle screw lock-nut on both carburetters. Push the cold start (choke) fully home then pull it out again to its full extent and recheck the fast idle speed.

34. Fit the appropriate blanking plug and cap to the mixture screw recess and idle adjusting screw.

35. Fit the carburetter air intake elbows and air cleaner.

PETROL FUEL SYSTEM

1191

PETROL F U EL SYSTEM

SYMPTOM

DIFFICULT S T A R T I N G W H E N C O L D

I I F F I C U L T S T A R T I N G W H E N H O T

A C K OF ENGINE P O W E R

:RRATIC S L O W -R U N N I N G O R iTALLING O N D E C E L E R A T I O N

:XCESSIVE F U E L C O N S U M P T I O N

V8

ENGINE CARBURETTER

FAULT DIAGNOSIS

POSSIBLE CAUSE CURE

Insufficient choke action

Fast idle adjustment incorrect

Float chamber level too IOW

Carburetter llooding

No fuel supply to carburetter

Choke sticking 'on'

Blocked air cleaner

Float chamber level too high

No oil in damper or oil too thin

Air valve sticking

Water in fuel

Float level too low

Incorrect jet sctting

Zarburctter air leaks

Vlanifold air leaks l a m p e r oil too thick. N o oil in damper

4ir valve sticking

3locked air cleaner l a m p e r oil too thick

-,.-....--. ... l:.."*-,l

I I C V I I C C L l y U",U>'CU

-,.-I.

.._^

CLLII,UIC;LLCI

'loat level too high

Norn jets and necdlc ncorrect needle

:hoke sticking 'on'

<ngine fault

Check action of cold start unit to ensure that the choke is being applied fully - adjust choke cable. Check position of cold start adjuster -

Check and adjust fast idle setting. Check linkage between choke and throttle for distortion

Check needle valve for sticking -

Chcck tloat level setting. Chcck inlet corinection filter for blockage. Check externa fuel system in accordance with fuel system fault diagnosis

Float punctured

Fuel pump pressure too high

Float level too high

Check filters and pump for blockage

Check fuel tank breather and fuel lines for blockage

Removc fuel pump and check operation

Overhaul or f i t new pump

Check to ensure choke is returning to fully

'off' position; reset as necessary

Fit new air cleaner elements

Check float level setting.

Check float arms for distortion. Check needlc mlve for sticking. Punctured float. fuel pump x e s s u r e too hieh

Zhcck level of oil in damper, and fill to corrcc eve1 with oil of a viscosity of S.A.E.20 l h e c k air valve assembly moves freely and

-eturns under spring load centre jet issem bl y lheck diaphragm for cracks or porosity- Zenitt f water is present in float chamber, the omplete fuel system should be drained, fuel omponcnts should be dismantled, inspected

'or contamination, paying particular attention o filters.

Sheck float chamber level

-heck for needle valve sticking

:heck and reset jet settings in accordance vith carburetter overhaul instructions

:heck throttle spindle and bearings for wear

-heck inlet manifold gaskct for leakage.

:heck inlet manifold for cracks and distortion i f mating faces. Check gaskct between arburetter and manifold. Check condition

1f vacuum advance pipe and connections.

:heck vacuum servo pipes and connection>

?heck and refill to correct level with oil pecificd

:lean and check freedom

:it new air clcaner elements

Ceplace with correct grade rlllU

> I \ ) W I-..

:..

.,-..--, .,..

..^ iith carburetter tune and iidjusr instructions

:heck and reset float lcvcl k c k and repiacc a s ncccssary

:heck needlc typc

:heck to ensure choke is rcturning to fully position. r c x t a s ncccssary r e Engine Fault diapnci\is

PETROL FUEL SYSTEM

LAND ROVER 110 TWIN TANK INSTALLATION

Description

The fuel system includes two fuel tanks, one at t h e rear of the vehicle and an additional fifteen gallon

(68,20 litres) capacity tank on the right-hand side of the vehicle. Both tanks contain an electrically operated submerged fuel pump in addition to a fuel level indicator unit in each tank. An ignition controlled switch on the control panel enables the driver to select the tank to be used. The switch also energises the fuel level indicator unit of the tank selected and records the fuel level on the single indicator dial. When t h e ignition is switched ‘on’ the pump in the selected tank will draw fuel into the carburetter float chamber via a paper element type filter and a vapour separator. To prevent fuel vapourisation and air locks a spill return system is incorporated in the fuel pipe layout to pass back vapour and excess fuel from the vapour separator to the tank in use through a restrictor and a solenoid operated valve.

The valve, which is encrgiscd by the tank selection switch, closes the port to the tank not i n use and simultaneously opens the port to the sclccted tank. The restrictor is necessary to prevent fuel by-passing the carburetter and flowing back to the selected tank through the spill return systcm.

In addition, a non-return valve is enclosed inside the hose connection of the supply pipe from t h e rear and side tanks to prevent the possibility of a back-flow of fuel along the supply lines to t h c fuel tanks.

ST1683M

FUEL TANK SELECTION SWITCH

A. Fuel tankswitch

LAND ROVER 110 REAK TANK AND 90 SIDE TANK

INSTAL1,ATION

Description

Fuel drawn by the electrically operated in-tank pump, is delivered to a paper element type filter. Situated bencath the right-hand front footwell attached to a chassis outrigger from the filtcr, fuel enters a vapour separator located on the left-hand side of the bulkhead in the engine compartment. Fuel finally cntcrs the carburetter float chamber from the port at the base of the vapour separator. The vapour separator comprises part of the spill return system and its purpose is to prevent fuel vapour causing air locks in the supply to the carburetter. Vapour and excess fuel flows back into the restricter fitted !e the spi!! return port on the vapour separator. The restrictor is designed to assist in maintaining a constant fuel level in t h e vapour separator bowl and to prevent fuel flowing back to the tank at the same rate as the delivery.

FUEL FILTER

A . Fuel “Iter

From fuel pump to filter pipc

C. From fuel filter to carburetter via vapour separator

PE TROL F U EL S YST E M

119

VAPOUR SEPARATOR

A. Vapour separator

B. Spill return to side tank

C. Restrictor and spill return to solenoid valve

D. Outlet from separator to carburetter

NON-RETURN VALVE

A. Non-return valve

B. Spring

C. Ball

SPILL RETURN SOLENOID VALVE

A . Solenoid valve

B. Spill return to side tank

C. Spill return to rear tank

D. To carburetter via filter and vapour separator

ST1844M

FUEL PUMP

A. Pump and motor

B. Filter

C . Gasket

D. Electrical terminals

E. Outlet pipe

F. Fixing plate to tank

G. Plastic tie clip refit pump e

PETROL FUEL SYSTEM

LAND ROVER 110 TWIN TANK FUEL SYSTEM

PETROL FUEL SYSTEM

.!'::.:

LAND

ROVER

110 TWIN TANK

FUEL SYSTEM

KEY TO FUEL LINE INSTALLATION

2. In-tank fuel pump -side tank.

3. Fuel gauge tank unit - rear tank.

4. Fuel gauge tank u n i t -side tank.

5. Spill return solcnoid.

6. Fuel filter.

7. Fuel supply pipe -

8. Pipe, filter to vapour scparator.

9. Vapour separator.

10. Vapour separator outlet to carburetter.

1 1. Spill return pipe to fuel tank via restrictor and solenoid valve.

12. Spill rcturn pipe to side tank from solenoid.

13. Spill rcturn pipe to rear tank from solenoid.

14. Fuel filler -

15. Breather pipc -

16. Fuel filler -

17. Breather pipe -

18. Drain plugs side and rear tanks.

19. Non return valve incorporated in hose.

1191

P ETROL FU E L S YSTEM

LAND ROVER 110 BASIC FUEL SYSTEM

1. In-tank fuel pump.

2. Fuel gauge tank unit.

3. Fuel supply pipe to filter via connector.

4. Fuel filter.

5 . Fuel supply pipe filter to vapour separator

6 . Vapour separator.

7. Vapour separator, outlet to carburetter.

8. Spill return pipe to fuel tank via restrictor.

9. Fuel filler.

10. Breather hose.

11. Restrictor.

12. Fuel tank drain plug. f. f

*:+

;

LAND ROVER 90 BASIC FUEL SYSTEM

I . In-tank fuel pump.

2. Fuel tank gauge unit.

3 . Fuel supply pipc to filter.

4. Fuel filter.

5. Fuel supply pipe filter to vapour separator

6.

Vapour separator.

7. Vapour separator, outlet to carburctter.

8. Spill return pipc to fuel tank via restrictor.

9. Fuel filler.

10. Breather hose.

11. Restrictor.

12. Fuel tank drain plug.

PETROL FUEL SYSTEM

REMOVE REAR TANK FUEL PUMP

To renew the pump it is first necessary to remove the fuel tank from the vehicle. Before commencing the following instructions it is essential that the

WARNINGS and safety precautions concerning fuel tank draining and removal are studied and observed.

These precautions are included in the introduction to this and each of the five books comprising the workshop manual for the Ninety and One-Ten vehicles.

1. Move vehicle to well ventilated area and disconnect the battery.

2. Remove the fuel tank drain plug and allow the fuel to drain into a suitable receptacle and refit the

Plug.

3. Working from the right-hand side of the vehicle disconnect the fuel feed pipe and the spill return at the rubber connections.

4. Disconncct the fuel filter hose and breather hose from the tank.

5. Whilst, noting the cable colours, disconnect the electrical leads from the fuel gauge unit at the left-hand side of the vehicle.

6. If the vehicle is fitted with a towing ball drop-plate with support bars the bars must be removed.

7. Remove the eight nuts and bolts securing the anti-roll bar to the chassis and push the roll bar down to provide access to the tank.

8. Remove the left-hand lashing eye to facilitatc removal of the tank.

9. Place a support under t h e tank, preferably one which will enable the tank to be progressively lowered.

10. Remove the two nuts retaining the forward end of the tank.

11. Remove t h e two nuts securing the rear of the tank.

12. Carefully lower the tank sufficiently to enable the electrical leads to the fuel pump to be diconnected.

13. Finally rcmove the tank from the vehicle together with the pump and rear section of the fuel feed pipe.

14. Disconnect the rear section of the feed pipe from the pump.

1.5. Remove the five retaining screws and withdraw the fuel pump and sealing ring from the tank.

16. Cover t h e pump aperture in the tank to prevent the ingress of foreign matter.

Fitting fuel pump

CAUTION: On some early models a modification was carried out to the fuel pump to prevent the possibility of the contacts earthing. These pumps can be recognised by a black plastic tie clip as illustrated. See Fuel System description. If the fuel tank only is being renewed and the original pump is being re-fitted, ensure that the tie clip is correctly positioned.

Fit the pump into the tank with a new Sealing ring so that the outlet pipe is directed towards the front of the vehicle and the electrical connections to the rear.

18. Offer-up tank to thc chassis and connect thc electrical leads black to negative (-) white to positive (+).

19. Locate front of t h e tank on the two captive bolts and secure with the mounting rubber, flat and spring washer and nut.

.-w

ST1679M

, >

Y;:. :* .I a .

20. Secure the rear of the tank with the two captive bolts, plain washer and nyloc nut.

PET ROL F U EL SYS TE M

1191

j l ”

J z

..,::”

ST1676 M

7. Cover the pump aperture in the tank to prevent the ingress of foreign matter.

CAUTION: On some early models a modification was carried out to the fuel pump to prevent the possibility of the contacts earthing. These pumps can be recognised by a black plastic tie clip as illustrated. See fuel system description. If the fuel tank only is being renewed and the original pump is being re-fitted, ensure that the tie clip is correctly positioned.

21. Connect the fuel feed pipe.

22. Connect the spill return pipe.

23. Connect the fuel filter hose and breather pipe to the tank.

24. Fit the left-hand lashing eye.

25. Fit the anti-roll bar.

26. Fit the drop plate support bars-

27. Connect the fuel gauge unit leads.

28. Reconnect battery, and check operation of pump and change-over solenoid - fitted.

REMOVE SIDE TANK FUEL PUMP

1. Move the vehicle to a well ventilated area, extinguish all naked lights and disconnect the

3. vehicle batteries.

Remove the right-hand side front seat cushion.

Move the carpet aside, where fitted and unclip and

4. remove the seat base cover.

Disconnect the two Lucars from the fuel pump.

5 . Disconnect the fuel outlet pipe from the pump.

6 . Remove the five retaining screws and withdraw the pump and sealing ring.

Refitting

8. Insert the pump and new sealing washer into the tank so that the outlet pipe is directed towards the left-hand side of the vehicle and the electrical connections to the right.

9. Secure the pump with the five screws tightening evenly.

10. Fit the supply pipe to the pump outlet and tighten the hose clip.

11. Connect the white/grccn wire to the positive (+) terminal and the black wire to the negative [-) terminal.

12. Connect the batteries, switch on ignition and operate the tank selection switch, if it is a twin tank installation and check that the pump operates.

13. Switch off ignition, fit the seal base c w e r and carpet and refit the seat cushion.

DIESEL FUEL SYSTEM

FUEL INJECTORS

CHECKING NOZZLE ASSEMBLIES

WARNING:

Do

not allow the fuel spray to contact the person otherwise injury may result from skin penetration.

When an injection nozzle is considcrcd to be t h e cause of irregular running and loss of power, a quick check may be made by loosening the fuel feed pipe union nut on each nozzle in turn, whilst the engine is idling at approximately 1,000 rev/min.

If the injection nozzle assembly being checked has been operating properly, there will be a distinct reduction i n engine speed accompanied by obvious roughness, but a faulty injection nozzle may make little or no difference to the engine note when its fuel feed pipe is loosened.

Spray check

1. Remove the fuel spill gallery pipe complete from the injection nozzles.

2. Disconnect the fuel feed pipe (injection pump to nozzle) from the nozzle to bc testcd and from the injection pump.

3. Rcleasc t h e fixings and withdraw the suspected injection nozzle assembly; reconnect t h e pipe and nozzle assembly to t h e injection pump in a position whereby fuel ejection may be observed.

4. Loosen the union nuts securing the remaining fuel pipes to injection nozzles.

5 . Whilst the starter turns the engine over, observe the manner in which fuel issues from t h e nozzle and' compare thc spray form with the correct form as illustrated.

Very little fuel should issue from the main spray hole with the engine turning over at starter specd but a fine spray comparablc to that illustrated

6. should be ejected from the auxiliary spray holc.

If the ejected fuel is more in the form of a liquid jet or issues from the main pintle hole, then the nozzle and holder assembly should be removed for overhaul and a replacement unit fitted. e

8. Connect t h e spill gallery pipe with the bolt and two washers.

NOTE: The above illustration shows the D.P.A. pump fitted to the 3.25 iitre diesei engine.

PRIME FUEL SYSTEM

Procedure following fuel filter or sedimentor service

When models fitted with a sedimentor have had thc water drained only from the sedimentor bowl, no priming is necessary as t h e water is replaced by fuel automatically syphoned from thc tank. However, if the sedimcntor has been dismantled and air has entered the body, or where the fuel filter element has been replaced and the filter bowl cleaned, then the system must be primed as follows:

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...

. .

C . . .

1. D o not attempt to start the engine hoping to draw the fuel through in this way, othcrwisc the full priming procedure will be necessary.

2. Slacken the bleed pipe banjo bolt on the top of the main fuel filter.

DIESEL FUEL SYSTEM

1191

.. ..,

' ,. ... . .

...

' . I

3. Operate the hand priming lever on the mechanical pump, until fuel free from bubbles emerges.

Always ensure that fuel pump lever is on the bottom of the operating cam when priming the fuel system, otherwise maximum movement of the priming lever cannot be achieved.

4. Tighten the bleed pipe banjo bolt whilst the fucl is still emerging.

5 . Operate the hand priming lever once or twice to clear t h e last bubbles of air into the filter bleed pipe.

6. Start engine in normal way and check for leaks.

Procedure when fuel system has been drained

7. Carry out instructions 1 to 5 inclusive.

8. Release air v e n t screw on distributor body.

Illustration A - 2.25 litre D.P.A. pump

Illustration B - 2.5 litre D.P.S. pump

9. Operate t h e fuel pump hand priming lever until fuel free of air cmerges.

10. Rctighten the air vent screw.

11. To ensure that all air is exhausted from the pump i t may also be nccessary to slacken air vent screw in the distributor control cover and repeat instructions 9 and 10. 2.25 litre engine D.P.A. pump only.

12. Start the engine in the normal way and check for leaks.

Procedure when distributor pump has been drained

13. Carry out instructions 8 to 12 inclusive.

FUEL INJECTION PUMP

When Diesel engines are operated at high altitude it is recognised that the reduced air density causes a reduction i n the weight of air drawn into the engine cylinders, which results i r i incomplclc combustion of the injected fuel at full throttle, unlcss this is rcduced in proportion to the reduction in air density.

To compensate for these variations and to avoid excessive fuel consumption, accompanied by excessive exhaust smoke, the amount of fuel delivered to the cylinders must be reduced to suit the conditions under which the engine is required to operate. For every

330 metres (I000 feet) above 990 metres (3000 feet) the fuel delivery must be reduced by 3%.

Adjustments to the D.P.S. pump, however, must only be carried-out by an authorised C.A.V. Dealer.

.i.

DIESEL FUEL SYSTEM

OVERHAUL FUEL INJECTORS

Service tools:

271483 or

18G109 or

Diesel tune 111

278182 or

18G109B or

Diesel tune 102

278181 or

18G109E

605002 or

18G1487 or

FT9101

Injector nozzle testing and setting kit

Adaptor Pintaux Injector

Injector nozzle flushing tool

Injector nozzle cleaning kit

DISMANTLE

1. Remove the injectors from the engine.

2. Disconnect the injectors from the fuel spill rail.

3. Remove the combined locknut and end cap.

4. Withdraw the sealing washer.

5. Unscrew the pressure adjusting screw.

6.

Withdraw the pressure spring.

7. Withdraw the valve spindle.

8. Unscrew the cap nut.

9. Withdraw the nozzle valve and body.

12. Clean the three oil feed passages in the nozzle body with a wire or drill of 1,5 mm (0.062 in) diameter.

13. Remove the carbon from the annular recess with the tool illustrated.

,,: 5,

ST 1107M

- . +

6 ---

14. Remove the carbon from the valve seat, using the appropriate tool with a rotary motion.

15. Select the appropriate size probe from t h e pocket of cleaning kit and secure it in the pintle hole cleaner.

Insert the probe into the bore of nozzle valve body and allow the end to extend through the main fuel outlet, then turn in a rotary manner to remove carbon.

ST 1106M

Cleaning and inspecting

10. Soak the component parts of the assembly in Shell

Calibration Fluid to loosen carbon deposits, but do not allow parts of any one assembly to be interchanged with those of another.

11. Brush away all external carbon deposits from component parts with a brass wire brush and return them to the fluid bath. Particular care must be exercised when cleaning the pintle and seat of nozzle valve to avoid scratching or scoring, which could result in spray distortion.

ST 1108M continued

:-;

..\..*

16. Carbon may be removed from the nozzle valve cone by inserting the valve into the tool illustrated and then rotating it alternately in a clockwise then anti-clockwise manner whilst pressing the valve inward.

If

the nozzle is blued or the seating has a dull circumferential ring indicating pitting or wear, the nozzle body and valve should be returned to a

CAV Service Agent and replacement parts fitted.

Do not attempt to lap the nozzle valve to body.

This process requires special equipment and training.

17. Clean the auxiliary spray hole using the special tool fitted with probing wire 0,20 mm (0.008 in) diameter.

NOTE: Allow 1,s mm (0.062 in) only to extend from the chuck and thus minimise the possibility of the wire bending or breaking while probing. Great care must be taken to prevent breakage of the wire inthehole.

DIESEL FUEL SYSTEM

19. With the flushing tool secured to the nozzle testing outfit, fit the nozzle body (spray holes uppermost) to the flushing tool and pump test oil through vigorously. This flushing process is necessary for the removal of any tiny carbon parricles which may have become lodged in the body after scraping and probing.

ST 1109M

18. Examine the pressure faces of nozzle body and nozzle holder to ascertain their freedom from scoring and scratches. These surfaces must be perfectly smooth.

ST 1111M

Assemble

20. Fit the nozzle valve to nozzle and check for freedom of movement.

21. Immerse the nozzle body and valve in the fluid bath and assemble whilst submerged.

22. Wash the remaining components and assemble the injector in the sequence illustrated during the dismantling.

23. Set the injection nozzle assembly in accordance with the following test procedure.

Bench test injector nozzle and holder assembly

24. To check a nozzle assembly and to ensure that it is functioning correctly, a setting outfit, as illustrated, is essential. A bench covered with linoleum or non-ferrous sheet metal is most suitable for mounting the outfit; such a surface facilitates the cleanliness essential when checking nozzle parts.

Between the bench and setting outfit, a tray, also

-c

U 1

- - - c

I1u1I-lc1fuu>

--.-

1 - L - . . l J be positioned to prevent spilt fuel spreading. Small containers may be attached to the bench to isolate the component parts of each assembly. These parts are carefully mated by t h e manufacturers and must not be interchanged. Lastly, a small bath with a cover, containing Shell Calibration Fluid for washing components, should be kept conveniently near.

DIESEL FUEL SYSTEM

25. The efficient operation of the injection nozzle assembly is dependent on four main conditions, as follows:

The nozzle valve must open at 135 Ats.

The rate of back leakage must be within 150 to

100 Ats.

Seat tightness must be sufficient to prevent leakage.

Spray form must compare favourably with the illustrations.

26. Pressure setting, back leakage and seat tightness tests may be made by coupling the injection nozzle and holder assembly direct to the pressure feed pipe on the setting outfit, but an adaptor must be fitted between the pipe and injection nozzle and holder assembly when testing spray form. This adaptor, see instruction 38, increases the pressure of fuel to the injection nozzle and holder assembly sufficiently for the main and auxiliary spray form to

6e determined.

Test procedure

WARNING: The injection nozzle must not be allowed to point towards the operator when spraying and the hands must never be allowed to contact the spray which has a force that can penetrate the flesh.

27. Remove the cap from the setting outfit container and fill with 0,8 litre (1.5 pints) of Shell Calibration

Fluid.

28. Air vent the system by removing the vent screw, allow oil to flow freely for a few seconds and replace the screw whilst the flow continues.

29. Operate the pump handle until fluid flows from pipe.

30. Connect the injector and holder assembly to the pressure feed pipe with the nozzle pointing downwards. The length and bore of this pipe is important and replacement pipes must be approximately 75 mm (2.8 in) between the union nuts and of 3 mm (0.118 in) bore.

31. Close the check valve to keep the pressure gauge out of circuit and smartly operate the hand lever several times to expel all air from the system.

Leak-back test

32. Adjustment is made by removing the combined end cap and locknut from the nozzle holder, and turning the adjusting screw clockwise to increase and anti-clockwise to decrease the opening pressure.

33. Fit assembled injector to nozzle setting outfit and adjust to open at 160 to 170 atmospheres then pump up to just below this figure, release handle to allow the needle of gauge to fall naturally. Time the pressure drop from 150 atmospheres down to

100 atmospheres.

34. This should be not less than 5 seconds for the original nozzle and not less than 7 seconds if a new one is to be fitted, and not more than 36 seconds for either with oil temperature 10" to 21°C (50" to

70°F).

35. Check externally the top and bottom of nozzle cap nut and pressure pipe union nuts for signs of oil leakage. If leakage occurs at the nozzle cap nut, remove the nut and examine the pressure faces of nozzle holders and nozzle body (see item 18) for presence of foreign matter or surface scoring, before tightening further.

A leak-proof nozzle assembly with an excessive rate of pressure drop indicates a worn nozzle valve; the nozzle valve and nozzle body should be renewed.

ST 1 1 127M

Pressure setting

36. The selected operational opcning pressurc of the nozzle valve is 135 atmosphcrcs. Readjust to this setting in t h e manner described in item 32. s"

Seat tightness

37. Wipe the bottom face of the injection nozzle dry and raise the pressure in the system to 125 atmospheres. A slight dampness on the bottom face is permissible, but blob formation

01' indicates a badly seating valve in which case the assembly should be dismantled for further examination.

Spray form

38. Fuel delivery to the injection nozzle assembly when testing spray form must be characteristically similar to fuel delivery under normal operating conditions and to effect these conditions an adaptor (CAV f~

Y7044872) must be fitted between the injection

;. , nozzle assembly and the pressure pipe. continued

DIESEL FUEL SYSTEM

:.:T

. .

Y .

39. The adaptor differs mainly in the cap nut and nozzle valve from the ordinary type of injection nozzle and holder assembly as fitted to the engine; the nozzle valve has no pintle.

40. The cap nut is extended, bored and threaded to receive nozzles for testing.

41, Connect the adaptor assembly to the pressure pipe.

42. Remove the end cap and adjust the opening pressure of the nozzle valve to 220 atmospheres.

43. Screw the injection nozzle and holder assembly to be tested, into the adaptor.

44. With the check valve closed, operate the handle smartly to expel air from the system. The auxiliary spray form may be tested at 60 strokes per minute and the main spray at 140. Spray development from starting to running speeds is illustrated, this

* illustration should be referred to and compared with the spray form of nozzles under test.

Spray formation should be well formed and free from splits or distortion. A slight centre 'core' can be disregarded. Observe the main spray through

360 degrees to ensure a uniform spray. d

ST 1115M

45. When satisfactory, fit the combined locknut and end cap, connect the injectors to the fuel spill rail and fit them to the engine.

FITTING FUEL INJECTORS

The steel sealing washer fitted below the injector nozzle is to ensure that combustion does not take placc around the nozzle body and cause it to overheat. A washer which has been used more than once, or an incorrectly fitted washer may cause the nozzle to overheat and result in that cylinder misfiring.

1 . Ensure that the new washers are separated from each other and are clean.

2. Use a length of thin welding wire to guide one washer only into each port with the domed side toward the injector as illustrated. Ensure that only one washer is fitted to each port. continued

. .

ST1114M

I '

1191

DIESEL FUEL SYSTEM

3 . Lightly grease the copper washer into position on each injector before fitting to the cylinder head.

4. Fit the injector and evenly tighten the retaining nuts to the correct torque 6 to 8 Nm (4 to 6 Ibs ft).

Uneven or overtightening of the injector nuts could distort the nozzle and cause misfiring when normal running temperature is reached.

5 . Reconnect the injector pipes but d o not overtighten thc union nuts.

HAND THROTTLE -

Petrol and Diesel four cylinder engines

Adjust

1. Slacken the lock nut on the cable adjuster and turn the adjuster to remove all slack from the cable and tighten the locknut.

NOTE: The first illustration petrol engine and second illustration Diesel engine.

A . ) Foot pedal cable adjuster

B.) Hand throttle cable adjuster

THROTTLE PEDAL ADJUSTMENT -

Petrol and Diesel four cylinder engines

1. After renewing the throttle cable, remove any slack in the cable by adjustment of the cable adjuster at the engine end.

2. Depress the throttle pedal, by hand, .to the full extent of the carburetter, DPA or DPS pump linkage, and adjust thc pedal stop screw to take up all clearance between the screw and scuttle panel.

Make sure that n o strain is placed upon the carburetter or pump linkage.

. ..

ST1835M

STlfiR8M

DIESEL F U EL SYSTEM-TURBO CHARGED ENGINE

GENERAL SPECIFICATION DATA

2.5 Litre Turbo Charged Diesel Engine

Number

of

cylinders .............................................. 4

Bore .................................................................. 90,47 mm (3.562 ins)

Stroke ............................................................... 97,OO mm (3.822 ins)

Capacity ............................................................. 2495 cc

Compression ratio

Valve charger

Turbo charger

................................................ 21:l

...................................................... 0.

..................................................... Garrett T2

Crankshaft

Main bearing journal diameter ................................ 63,487-63,500 mm (2.4995-2.500 in)

Regrind dimensions:

63,246-63,2333 mm (2.490-2.4895 in)

Crankpin journal diameter

.................. Use 0.010 in

U/S

bearings

...................................... 58,725-58,744 mm (2.312-2.31275 in)

Regrind dimensions:

58,48985-58,4708 mm (2.30275-2.30200 in)

Crankshaft end thrust

.......... Use 0.010 in U/S bearings

............................................ Taken on thrust washers at centre main bearing

Ciankshaft end-float ............................................. 0,05-0,15 m m (0.002-0.006 in)

Main bearings

Number and type ................................................. 5 halved shells without oil grooves

Diametrical clearance ............................................ 0,018-0,061 mm (0.0007-0.0024 in)

Connecting rods

Length between centres ......................................... 175,38-175,43 m m (6.905-6.907 in)

Diametrical clearance (big-end bearings)

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

0,025-0,075 m m (0.001-0.003 in)

End-float on crankpin ............................................. 0,15-0,356 m m (0.006-0.014 in)

. .

Pistons

Type ................................................................. Aluminium alloy ‘V’ shaped valve recess in crown

Skirt diametrical clearance

(at right angle to gudgeon pin) ................................. 0,025-0,05 m m (0.001-0.002 in)

Gudgeon pins

Type ................................................................. Floating

Fit in piston

Diameter

......................................................... Hand push fit

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

30,1564-30,1625 mm

Clearance in connecting rod

(1.18726-1.18750 in)

.................................... 0,0196-0,0036 mm

(0.00077-0. U001 4 in)

Piston rings

Type :

Top

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

Second ......................................................

Chamfered friction edge, chrome plated

Taper faced

Oil control .................................................. Expander and rails

Gap in bore:

T o p .......................................................... 0,30 to 030 mm (0.011-0.019 in)

Second ...................................................... 0,25 to 0,45 mm (0.009-0.017 in)

Oil control .................................................. 0,3 to 0,6 mm (o.oii-O.u23

Clearance in piston grooves:

Top .......................................................... 0,14Oto0,180 mm (0.002to0.007 in)

Second ...................................................... 0,040 to 0,080 mm (0.001 to 0.003 in)

Oil control .................................................. 0,04 to 0,080 mm (0.001 to 0.003 in) continued

1191

DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE

Camshaft

Drive .................................................................

Location ............................................................

End-float

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

Number of bearings

Material

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

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

Valves

Seat angle:

Inlet ............................................................

Exhaust .......................................................

Head diameter:

Inlet ............................................................

Exhaust .......................................................

Stem diameter:

Inlet ............................................................

Exhaust .......................................................

Valve lift:

Inlet ............................................................

Exhaust .......................................................

Cam lift:

Inlet ............................................................

Exhaust .......................................................

Valve springs

Type .................................................................

Inner:

Length, free ..................................................

Length, under 8.0 kg (17.7 lb) load ....................

Outer:

Length, free ..................................................

Length, under 21 kg (46 Ib) load ........................

25,4 mm (0.1 in) wide dry toothed belt

Right-hand side (thrust side)

0,l-0,2 mm (0.004-0.008 in)

Steel shell, white metal lined

45"

39,12-39,37 mm (1.540-1.550 in)

33,25-33,50 mm (1.309-1.319 in)

7,912-7,899 mm (0.3114-0.3109 in)

8,682-8,694 mm (0.3418-0.3422 in)

9,85 mm (0.388 in)

10,26 mm (0.404 in)

6,81 mm (0.268 in)

7,06 m m (0.278 in)

Duplex Interference double 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)

Lubrication

System ...............................................................

System pressure, engine warm at 2000 rpm .................

Oil pump:

Type

Drive

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

End-float of both gears

Backlash of gears

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

Radial clearance of gears

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

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

Wet sump, pressure fed

2,5-4,57 kgf cm2 (35-65 Ibf in2)

Double gear 10 teeth, sintered iron gears

Splined shaft from camshaft skew gear

0,0260,135 mm (0.0009-0.0045 in)

0,025-0,075 mm (0.0008-0.0025 in)

0,l-0,2 mm (0.0034-0.0067 in)

Oil pressure relief valve:

Type ................................................................. Non-adjustable

Relief valve spring:

Full length

.................... ,.. .............................

Compressed length at 2.58 kg (5.7

lb)

load ...........

67,82 mm (2.670

61,23 mm (2.450 in)

Oil filter:

Type ........................................................... Screw-on disposable canister

FUEL

SYSTEM

Inspection pump .................................................. See 'ENGINE TUNING DATA'

Fuel lift pump type

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

Mechanical with hand primer

Pressure range

Fuel filter

Air cleaner

..................................................... 0,35-0,56 cm2 (5-8 Ibf in2)

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

Paper eiement

......................................................... Paper element type continued

42 a

F :

DIESEL FUEL SYSTEM -TURBO CHARGED ENGINE

........

:: :.

......:;....

::'

. .

Type

COOLING SYSTEM

................................................................. Pressurized spill return system with thermostat control, pump and fan assisted

Thermostat opening temperature

Pressure cap

............................. 82°C

........................................................ 1,0 kgf cm2 (15 Ibf in2)

Water pump type

Fan type

Radiator

................................................. Centrifugal

............................................................. 7 blade with viscous coupling

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

Combined engine coolant and oil cooler

CLUTCH

Type ................................................................. Verto diaphragm spring

Centre plate diameter (friction plate) ........................ 235 mm (9.25 in)

Facing material .................................................... Verto 791

Number of damper springs ..................................... 8

Damper spring colour ............................................ 2 off white/green -Suffix 'C'

2 off pigeon blue

Suffix ' A '

4 off ruby red - Suffix 'B'

Clutch release bcaring ........................................... Ball journal

TRANSMISSION

Type ................................................................. LT230T. Two-speed reduction on main gearbox output.

Front and rear drive permanently engaged via a lockable

Ratios Ninety and One Ten differential

.................................... High 1.4109:l

Low 3.3198:l

Rear axle

Type-Ninety models .............................................. Spiral bevel

Type-One Ten models ........................................... Hypoid; full floating shafts, Salisbury 8HA

Ratio-All models .................................................. 3.54:l

Front axle

Type-Ninety models .............................................. Spiral bevel

Front wheel drive

Ratio

................................................. Enclosed constant velocity joint

................................................................. 3.54: 1

Overall ratio (including final drive)

Ninety and One Ten models ....................................

In high transfer

Fifth

(Cruising gear)

Fourth

Third

Second

First

Reverse

4.15:l

4.991

7.53: 1

1 1.49: 1

17.90:l

18.48:l

In low transfer

9.76:l

1 1.75: 1

17.71:l

27.03: 1

42.1 1 : 1

43.47: 1

ELECTRICAL

Starter motor ...................................................... Paris Rhone type D9R91 12 volt, with reduction gear

. . . .

1191

DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE

ENGINE TUNING DATA

ENGINE

Firing order ........................................................

Injection timing ...................................................

1-3-4-2

13" R.T.D.C.

Timing marks:

. .

Valve timing ....................................................... Slot for peg i n flywheel and TDC mark on front pulley

Injection timing ................................................... Special tool 18G 1458 inserted in D.P.S. pump

Tappet clearances inlet and exhaust .......................... 0,25 m m (0.010 in)

Valve timing

Inlet opens .......................................................... 16"B.T.D.C.

Inlet closes .......................................................... 42" A.B.D.C.

Inlet peak ........................................................... 103" A.T.D.C.

Exhaust opens ..................................................... 51" B.B.D.C.

Exhaust closes

Exhaust peak

..................................................... 13" A.T.D.C.

...................................................... 109" R.T.D.C.

Valve lift

Inlet .................................................................. 9,85 m m (0,388 ins)

Exhaust ............................................................. 10,26 m m (0.404 ins)

Maximum governed speeds

Full load ............................................................. 4000 r.p.m.

N o load (flight speed)

Idle speed

............................................ 4400 k

........................................................... 670

Dic-down time

20 r.p.m.

..................................................... 4 seconds

DlSTKlBUTOK PUMP

Makehype .......................................................... CAV DPS type with boost control and two speed mechanical governor with auto advance and solenoid electrical shut-off. Tamper proof sealing on flight speed

Direction of rotation and fuel adjustment screws.

............................................. Clockwise, viewed from drive cnd

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

Back leakage rate 150-100 Atm:

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

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

Despatch nozzle ............................................. 8520A290A

INJECTORS

Makehype .......................................................... CAV Pintaux DES5385001

Nozzle size .......................................................... BDNO/SPC 6209

Opening pressure (working pressure) ........................ 135 to 140 Atmosphercs

Injector pipe type ................................................. High pressure multi-bundy size .................................................. 1,94 to 2,06 m m length .............................................. 457,2 mm (18 ins)

HEATER PLUGS ., iviaiteitype n .......................................................... rrobe type, C'nampion CE63 i i v ~ i i s iicjiiiiiiai

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

TURBO-CHARGER

Makehype .......................................................... Garrett T2

Maximum boost pressure ....................................... 48 cm H G (9.3 P.S.I.G.) measured at wastegate actuator

"T" piece

DIESEL F U EL SYST E M

TORQUE WRENCH SETTINGS

191

TURBO-CHARGER FlXINCS

Stud-Turbo charger to exhaust manifold

Nut-Turbo charger to exhaust manifold

Adaptor-Oil feed to cylinder block

Adaptor-Oil drain to cylinder block

Pipc-Oil feed to turbo charger

Pipe-Oil drain

Stud-Outlet elbow to turbo charger

Nut-Outlet elbow to turbo charger

Heat shield support to inlet manifold

Stud-Exhaust manifold to cylinder head

Nut-Exhaust manifold to cylinder head

Screw-inlet and exhaust manifold to cylinder head

22-28

2 1-26

22-28

15-22

32-48

22-28

2 1-26

22-28

30-40

28-36

30-40

Ibf.ft

16-2 1

15-19

16-21

11-16

23-35

16-2 1

15-19

16-2 1

22-30

2 1-26

22-30

RECOMMENDED ENGINE OILS

The following list of recommended engine oils for temperate climates - ambicnt temperaturc range

10°C to 35°C should be used for oil changes and topping up. T h e y are SHPD (Super High Performance Diesel) oils that allow a maximum of 10,000 km (6,000 miles) between oil and filter changes.

CASTROL

MOBIL

SHELL

Vanellus C3 Extra 15/40

Deusol Turbomax 15/40

Delvac 1400 Super 15/40

Myrina 15/40

The following list of oils is for emergency use only i f the above oils arc not availablc. They can be used for topping-up without detriment, but if used for engine oil changing, they are limited to a maximum of 5,000 km (3,000 miles) between oil and filter changcs.

CASTROL

DUCKHAMS

ESSO

MOBIL

PETROFINA

SHELL

TEXACO

Vanellus C3 Multigradc 15/40

Dcusol RX Super 15/40

Hypergrade 15/50

Essolube XD-3 15/40

Delvac Super 15/40

Fina Dilano H P D 15/40

Rimula X 15/40

URSA Super Plus 15/40

Use only oils to MIL-L-2104C/D o r API Service levels C D or SE/CD-ISW/40 SECTION 10

MAINTENANCE SCHEDULE

The following additional maintenance is required for the turbo charged engine to that contained in t h c main schcdulc for the non-Turbo Charged 2.5 Litre Diesel cngine.

Every 500 km (250 miles)

Check engine oil level

At 1,600 k m (1,000 miles), 10,000 km (6,000 miles) and 20.000 k m (12,000 miles) then every 20,000 km (12,000 miles)

Check tappets, and adjust if n e c e s s q

Every 80.000 k m (48,000 miles)

- Check maximum turbo-charge boost pressure.

DIESEL F U EL SYSTEM-TURBO CHARGED ENGINE

TURBO-CHARGER

Removing

1. Remove thc bonnct.

2. Remove the hose connecting the air clcancr to the turbo-charger.

3 . Remove the turbo-charger heat shield fixings and remove the heat shield.

4. Release the clamp securing the turbo-charger elbow to the exhaust downpipe.

5 . Remove the inlet manifold to the turbo-charger hose.

6. Disconnect the boost control hose from t h e turbo- charger.

7. Disconnect from t h e turbo-charger the lubrication inlet pipe.

9. Remove the five nuts to release the exhaust elbow and gasket from the turbo-charger.

10. Release the lock tabs and removc the four nuts securing the turbo-charger to the exhaust manifold and remove the turbo-charger and gasket.

8. Disconnect, at the flexiblc hose, the lubrication drain pipe from the turbo-charger.

\ \ \ \

\ \ \ \ \

Fitting

11. Fit the raised bead side of a new gasket uppermost to the exhaust manifold and fit and secure the turbo-charger with the four nuts, tightening evenly to the correct torque and secure with lock tabs.

12. Fit the exhaust elbow, using a new gasket, to thc turbo-charger and retain with the five nuts tightening evcnly to the correct torque.

DI E SE L FUEL S YSTEM T U RBO CHARGED ENGINE

119

ST1863M

13. Fit the exhaust downpipe to the turbo-charger elbow and tighten the clamp bolt.

14. Connect the lubrication inlet pipe to the turbo- charger.

15. Fit the oil drain pipe to the flexible connection.

16. Connect the boost control pipe to t h e turbo- charger.

17. Fit the hose connecting the inlet manifold to turbo- charger.

18. Fit the heat shield.

19. Fit the air cleaner to turbo-charger hose.

20. Immediately prior to starting the engine release the oil inlet pipe to the turbo-charger and fill the centre housing with a recommended makc and grade of engine oil and re-fit the pipe.

CHECKING TURBO-CHARGER BOOST PRESSURE

1. Disconnect, from the turbo-charger, t h e hose to the actuator and insert, into the free end a suitable

‘T’ piece.

2. Connect a short length of slave hose to the turbo- charger and connect t h e other end to the ‘T’ piece.

3 . Connect a further slave hose to the third leg of the

‘T’ piece and the other end to a pressure gauge capable of reading in excess of 50 cm of Mercury.

The pressure gauge hose must be long enough to reach into the cab of the vehicle so that the gauge can be observed by the driver or passenger.

4. Drive t h e vehicle in the normal manner (2,500-

3,000 r.p.m. full load) and observe the maximum pressure obtained and compare with the figure in

Data Section 05.

RENEW TURBO-CHARGER ACTUATOR

1. Remove the two screws securing actuator bracket to the turbo-charger.

2 . Remove the nut and bolt securing actuator to the heat shield bracket and disconnect the hose.

3. Remove clip retaining actuator arm to the wastegate lever pin and withdraw the actuator from the engine.

4. Fit the replacement actuator with the two bolts and single nut and bolt. Tighten bolts to 12.5 to 14.0

Nm (111 to 124 in Ibs).

5 . Push the wastegate lever as far as possible towards the actuator and apply pressure to keep lever in this position.

6 . Pressurizc the replacement actuator to 57-62 cm

HgG (11-12 p.s.i.g) and hold this pressure.

CAUTION: Use only the threaded rod-end to make adjustments. Forcing the entire rod in or out will change the calibration with the possibility of damaging engine over-boost

7 . Screw the rod-end in either direction until the rod end eye will locate easily over the wastegate pin and secure with retaining clip.

8. Release the calibration pressure and tighten the rod end locknut. Reconnect the hose.

9. Check the boost pressure, on the road, as described earlier. The pressure should not fall below 44 or exceed 50 cm HgG (8.5 -

11911

DIESEL FUEL SYSTEM- TURBO CHARGED ENGINE

TURBO-CHARGER FAULT TRACING

It is important to be aware that when tracing a suspected fault in a turbo-charger that a turbo-charger cannot compensate for incorrect engine operation deficiencies in the air, or fuel intake systems, exhaust emission components or for damaged and worn engine internal parts such as valves and pistons. Before suspecting the turbo-charger, the engine should be checked against the tuning data in Section 05.

Replacing a sound turbo-charger with another will not correct engine deficiencies.

Systematic fault tracing of a suspected turbo-charger failure is important for t w o reasons. First, it must be found what, if anything, is wrong with the turbo- charger so that it can be cxchanged. Second, it must be decided what action is necessary to prevent a repeat failure.

In many cases, evidence pointing to the cause of a failure is destroyed while removing the turbo-charger from the engine. For example, if a turbo-charger failed because of a faulty installation, such as loose connections that allowed dirt to enter the compressor, this would not be evident once the turbo-charger was removed from the engine. Failure to correct the installation, such as reinstalling defective manifold flange Connections, could cause an identical failure of the replacement unit. T h e hose connecting the air cleaner to the compressor, which could contain dirt or harmful particles, should bc cleaned or renewed if necessary.

In general, the fault tracing procedures that can be done with the least effort and in the least amount of time should be done first. Do not remove and renew the turbo-charger until the following visual checks and repairs that can be made with the turbo-charger installed, have been done. DO NOT, UNDER ANY

CIRCUMSTANCES, DISMANTLE THE TUKBO-

CHARGER.

VISUAL INSPECTION

1. Inspect all connections within the intake system.

Tighten loose connections as required.

Replace damaged air intake components.

3 . Check the connection between the compressor and the engine intake manifold.

Tighten loose bolts as required.

4 Check exhaust system connections at turbine housing inlet and outlet flanges for oil leakage and loose connections. Tighten loose connections as required. If oil leakage exists, check the general condition of the engine.

5 . Check the oil line connections at the centre housing oil inlet and outlet ports for leakage.

Tighten loose connections as required. Start engine and recheck connections.

COOLING SYSTEM

1261

ENGINE PROTECTION

To prevent corrosion of the aluminium alloy engine parts it is imperative that the cooling system is filled with a solution of clean water and the correct type of anti-freeze, winter and summcr, or water and inhibitor if frost precautions are not required. Never fill or top-up with water only, always add an inhibitor

(Marstons SQ36) if anti-freeze is not used. NEVER

USC salt water with an inhibitor otherwise corrosion will occur. In certain territories where the only available water supply may have some salt content, use only clean rainwater or distilled water.

”

Recommended solutions

Anti-freeze Unipart Universal Anti-freeze or permanent type ethylene base, without methanol, with a suitable inhibitor for aluminium engines and engine parts.

Use one part of anti-freeze to one part water.

Inhibitor Marston Lubricants SQ36 inhibitor concentrate.

Use 100 cc of inhibitor per litre of water.

Anti-freeze can remain in the cooling system and will provide adcquatc protection for two years provided that the specific gravity of the coolant is checked before t h e onset o f t h e second winter and topped-up with new anti-freeze as required.

Land Rovers leaving the factory have the cooling system filled with 50% of anti-freeze mixture. This gives protection against frost down to minus 47°C

(minus 53°F). Vehicles so filled can be identified by a label affixed to t h e windscreen and radiator.

After the second winter the system should be drained and thoroughly flushed. Before adding new anti-freeze examine all joints and renew defective hoses t o make sure that the system is leakproof. Inhibitor solution should be drained and flushed out and new inhibitor solution introduced every two years, or sooner where the purity of the water is qucstionablc.

See the ‘General specification data’ section for protection quantities.

DRAIN AND FILL VS ENGINE COOLING SYSTEM

WARNING: Do not remove the radiator filler cap when the engine is hot because the cooling system is pressurized and personal scalding could result.

1. Remove the radiator filler plug.

2. Remove t h e radiator drain plug and allow thc coolant to drain, if neccssary, into a suitable container. Refit thc drain plug and ncw washer. The drain plug is situated on the left-hand side of thc radiator towards t h e bottom facing the engine compartment.

NOTE: Disconnect bottom hose to drain on radiators without a drain plug. Connect hose after draining.

3 . Remove the engine drain plugs, one each side of the cylinder block, beneath the exhaust manifolds.

Allow the coolant to drain and refit plugs and washers.

1261

CO OL ING S YSTEM

DRAIN AND FILL 2.25 LITRE PETROL AND

DIESEL AND 2.5 DIESEL SYSTEMS

WARNING: Do not remove the radiator or expansion tank filler caps when the engine is hot because the cooling system is pressurized and personal scalding could result.

1. Remove the expansion tanks and radiator filler

Plug.

4. To drain the expansion tank remove it from the vehicle, empty, flush-out and refit. If necessary renew the expansion tank hose.

5 . Make up a solution of anti-freeze and water in a scparatc container in the concentration required.

The cooling system capacity is quoted in the data scction. Therefore to allow for topping up and the expansion tank make up a quantity in excess of this quantity.

6 . If anti-freeze is not required use Marstons SQ36 in the concentration recommended as described under

‘Engine protection’. Make up a quantity in excess of capacity for topping up and expansion tank.

7. Make sure all drain plugs are tight and fill the system through the radiator filler plug until the coolant is just below the filler neck. Fit the plug but d o not over tighten.

8. Half fill the expansion tank with coolant and secure the cap correctly.

2. Remove the radiator drain plug and allow the coolant to drain, if necessary into a suitable container. Refit the drain plug with a new washer.

The plug is located on t h e left-hand side of the radiator facing the engine compartment.

9. Start and run the engine until normal operating temperature is reached. Allow the engine to cool and check the levels in the radiator and expansion tank and top up if necessary. Finally check all hose connections for leaks.

2 ST1146M

...

;

.......

,:,

.I, :

NOTE: Radiator without a drain plug, disconnected the bottom hose to drain. Reconnect after draining.

3. Remove the cylinder block drain plug, on the left- hand side of the engine, and allow coolant to drain completely before refitting the plug.

.: .

’

’.:

, I

ST1149M

’,;\

\ - . .

I I

4. To drain the expansion tank, disconnect the hose from the tank to the water pump. Drain and flush and reconnect the hose.

5 . Make up a solution of anti-freeze and water in a separate container in the concentration required.

The cooling system capacity can vary so rcfer to

‘Capacities’ under ‘General specification data’. To allow for topping up and the expansion tank prepare a quantity in excess of the capacity of the system concerned.

6. If anti-freeze is not required, use Marstons inhibitor

SQ36 in the recommended concentration, see under

‘Engine protection’. Prepare a quantity in excess o f t h e capacity for topping up and the expansion tank.

7. Check all hoses and drain plugs for security and fill the system through t h e expansion tank until approximately three quarters full.

8. Fit the expansion tank cap and radiator filler plug and run the engine until normal operating temperature is reached. Allow the engine to cool completely. Remove the expansion tank cap and if necessary top up to half full. Remove the radiator filler plug and check that the coolant level is just below the filler neck. Finally examine the cooling system for leaks. Tighten the radiator filler plug to

40-50 Ibs. in.

REMOVING THE RADIATOR (2.25 litre petrol and 2.25 and 2.50 diesel)

1. Disconnect the battery.

2. Drain the radiator by removing the drain plug at the bottom left-hand side of the radiator and releasing the expansion tank filler cap. See drain and fill cooling system.

3. Disconnect the overflow hose from the radiator.

4. The radiator is held in position by two brackets each secured by three screws. Remove the screws and brackets.

5. Disconnect the top and bottom hoses from the radiator.

6. Diesel engine

7. Disconnect thc vacuum pump hose from the pump and release it from the clips on the radiator cowling.

Petrol engine

8. Disconnect t h e air cleaner hose from the carburetter and remove the air cleaner.

9. Release t h e three fixings securing cowling to the engine.

10. Pull back the cowling towards the radiator and lift radiator and cowl.

11. Remove the five screws securing the cowling to t h e radiator and separate the two units noting that the cowling is held to the bottom of the radiator by two clips. continued

1261

CO OLI N G S YS T EM

FITTING THE RADIATOR

12. Locate the cowling into thc clip at the bottom of the radiator and secure it at the top with the five screws.

13. Lower the radiator and cowl assembly into position in the vehicle ensuring that the two pegs at the bottom of the radiator locate in the corresponding rubber pads in the crossmember brackcts.

14. Secure the top of the radiator with the two brackets and bolts.

15, Secure the cowling to the engine.

16. Connect the top, bottom and overflow hoses.

17. Diesel engine

Fit the hose t o the vacuum pump and secure it with the clips on the cowling.

Fit the air cleaner and connect the hose to the air

18. intakc manifold.

All engines

Check that the radiator drain plug (where fitted) is tight and f i l l t h e cooling system.

ST1151 M

A . Oil from engine to oil cooler.

B. Cooled oil from cooler to engine.

Start engine and check for oil leaks e--

-.-+

ST1684M

RADIATOR ASSEMBLY

VEHICLES.

Removing

1 . Disconnect the battery.

2. Remove the split pin and clevis pin securing the lower end of the bonnet stay and lift-off the bonnet.

3 . Remove the three screws each side securing the radiator left-hand and right-hand retaining brackets and remove the brackets.

4. Remove the four screws and withdraw the radiator cooling fan cowl.

5 . Disconnect the bottom hose from the radiator and drain the coolant.

6. Disconnect t h e oil cooler inlet and outlet pipes from the radiator and blank-off the pipes and radiator aperturcs to prevent ingress of dirt.

7. Disconnect the radiator top hose from the radiator and thermostat housing.

8. Disconnect expansion tank hose from radiator.

9. Lift the radiator from the engine compartment.

10.

If

the radiator is to be renewed, remove t h e oil cooler unions from the radiator and fit to the replacement radiator.

Fitting

11. Fit the radiator into position ensuring that the two pegs at the bottom

of

the radiator locate in the corresponding rubber pads in the cross member brackets.

ST18GYM

12. Fit the radiator top hose to the radiator and thermostat housing.

13. Conncct the radiator bottom hose.

14. Fit t h e expansion tank hosc to radiator.

15. Fit the fan cowl and secure with the four screws.

16. Fit the radiator left-hand and right-hand rctaining brackets.

17. Fit the oil cooler inlet and outlet hoses to the radiator.

Hose A to top of radiator.

Hose B to bottom of radiator.

.,.:..::

. ,

C T I n C n l "

JI l 0 U O l V l

18. Fit the bonnet and stay securing with the clevis pin and new split pin.

Filling radiator

19. Check that all hose clips are tight.

20. Remove the expansion tank cap.

25. Connect the battery and run the engine until normal running temperature is attained whilst checking for coolant leaks.

26. Stop the engine and allow it to cool completely.

27. Remove the radiator plug and check thc level and fit and tighten plug.

28. Top-up level of expansion tank and fit the cap.

21. Remove the radiator plug.

22. Fill the system with coolant using a mixture of water and anti-freeze or anti-corrosion inhibitor, through the expansion tank until1 the coolant is just below the level of the radiator plug hole. Continue filling until the expansion tank is half-full.

23. Fit the expansion tank cap and radiator plug.

Tighten the plug to 40-

24. Check the engine oil level in sump and top-up.

SYMPTOM

A- EXTERNAL L E A K A G E

B- INTERNAL L E A K A G E

C-WATER LOSS

D-POOR C I R C U L A T I O N

F - O V E K H E A T I N G

G-OVEKCWOLING

COOLING SYSTEM FAULT DIAGNOSIS

POSSIBLE CAUSE

I. Loose hose clips

2. Defective rubber hose

3 . D a m a g e d r a iator seams

4. Excessive wear in the water pump

5. Loose core plugs

6 . Damaged gaskets

7. Leaks at the heater connectionsor plugs

8. Leak at the water temperature gauge

Plug

CURE

1 . Tighten

2. Renew

3. Rectify

4. Renew

5. Renew

6. Renew

7 . Rectify

8. Tighten

I. Defective cylinder head gasket

2. Cracked cylinder wall

3 . Loose cylinder head bolts

I . Renew. Check engine oil for contamination and refill a s necessary

2. Renew cylinder block

3. Tighten. Check engine for oil contamination and refill as necessary

1. Boiling

2. Internal o r external leakage

3 . Restricted radiator o r inoperative thermostat

1 . Restriction in system

2. Insufficient coolant

3 . Inoperative water pump

4. I.oosc fan belt

5. Inoperative therinostat

2. Infrequent flushing and draining of system

3 . Incorrect anti-freeze mixtures

1. Ascertain the cause of engine overheating and correct as ncccssary

2. See items A and B

3. Flush radiator o r renew the thermostat as necessary

1. Check hoses for crimps, reverse-flush the radiator, and clear the system of rust and sludge

2. Replenish

3 . Renew

4. Adjust

5. Renew

1. Use only soft, clean water together with correct anti-freeze or inhibitor mixture

2. The cooling system should be drained and flushed thoroughly at least once a year

3 . Certain anti-frecze solutions have a cor- rosive cffect on parts of the cooling system. Only rccommcnded solutions should be used.

1. Poor circulation

2. Dirty oil and sludge in engine

3 . Radiator fins choked with chaff, m u d . etc.

4. Incorrect ignition timing

5. Insufficient coolant

6. Low oil level

7. Tight engine

8. Choked or damaged exhaust pipe or silencer

10.

Dragging brakes

Overloading vehicle

1 I. Driving in heavy sand or mud

12. Enginc labouring on gradients

13. Low gear work

14. Excessive engine idling

15. Inaccurate tcmperature gauge

16. Defective thermostat

1 . Defective thermostat

2 . Inaccurate temperature gauge

Sce item D

Refill

Use air prcssure from the engine side of the radiator and clean out passages thoroughly

4 . Check using electronic equipment

5. S e e i t c m D

6. Rcplenish

7. New engines arc very tight during the

'running-in' period and moderate speeds should be maintained for the first 1,000 miles (1500 km)

8. Rectify o r renew

9. Adjust brakes

10. I n the hands of the operator

11.

12.

In thc hands of the operator

In the hands of the operator

13. In the hands of the operator

14. In the hands of the operator

15. Renew

16. Rcnew

I. Renew

2. Renew

_......

, !9!:

. .

OVERHAUL RELEASE BEARING ASSEMBLY

I . Remove t h e clutch slave cylinder from the bell housing.

2. Withdraw t h e retaining staple, if fitted.

3. Remove the release bearing assembly.

5 . Remove the slipper pads - only.

6. Withdraw the relcase lever.

7. Discard worn parts.

8. Smear the pivot with grease and fit the release lever and retain with the spring clip and bolt -

9. Smear the release bearing sleeve inner diameter with Molybdenum disulphide base grease.

10. Fit the slipper pads.

11. Fit the release bearing assembly and retain with the staple. The staple is to aid assembly and has no other purpose. It may become dislodged in service,

. . without detriment.

Illustration A . V8 engine

CLUTCH

12. Coat both sides of the backing plate with a waterproof joint compound such as Hylomar

PL32M and locate the backing plate and dust cover in position on the slave cylinder.

13. Check that the push-rod clip is in position.

14. Fit the slave cylinder, engaging the push-rod through the centre of the dust cover and with the bleed screw uppermost. Secure the cylinder with the two bolts, tightening cvenly to the correct torque.

OVERHAUL MASTER CYLINDER

DISMANTLE

1. Remove the master cylinder from the vehicle.

2. Remove the circlip.

3. Withdraw the push-rod and retaining washer.

ST1134M ,,’ i

Illustration B. 4-cylinder engines

‘

L .

ST1135M

ST1136M

4. Withdraw the piston assembly.

If

neccssary, apply a low air pressure to the outlct port to expel the piston. continucd

STl137M

(33)

CLU TC H

5. Prise the locking prong of the spring retainer clear of the piston shoulder and withdraw the piston.

6. Withdraw t h e piston seal.

7. Compress the spring and position the valve stem to align with t h e larger hole in the spring retainer.

Assemble

14. Smear the seals with Castrol-Girling rubber grease and the remaining internal items with Castrol-

Girling brake and clutch fluid.

15. Fit the valve seal, flat side first, onto the end of the valve stem.

16. Place the spring washer, domed side first, over the small end of the valve stem.

17. Fit the spacer, legs first.

8. Withdraw the spring and retainer.

9. Withdraw the valve spacer and spring washer from the valve stem.

10. Remove the valvc seal.

STl140M

18. Place t h e coil spring over the valve stem.

19. Inscrt the retainer into the spring.

20. Compress the spring and engage thc valve stem in the keyhole slot in the retainer.

ST1139M

Inspection

11. Clean all components in Girling cleaning fluid and allow to dry.

12. Examine the cylinder bore and piston, ensure that they are smooth to the touch with no corrosion, score marks or ridges. replacements.

If

there is any doubt. fit new

13. The seals should be replaced with new components.

ST1141M

21. Fit the seal, large diameter last, to the piston.

22. Insert the piston into the spring retainer and engage the locking prong. c-

3 continued

CLUTCH

OVERHAUL SLAVE CYLINDER

DISM ANTL,E

1. Remove the slave cylinder from the vehicle.

2. Withdraw the dust cover.

3. Expel the piston assembly, applying low pressure air to the fluid inlet.

4. Withdraw the spring.

5 . Prise off the seal from the piston.

STl142M

23. Smear t h e piston with Castrol-Girling rubber grease and insert the assembly, valve end first, into

* the cylinder.

24. Fit the push-rod, retaining washer and circlip.

ST1144M

ST1143M

BLEED CLUTCH HYDRAULIC SYSTEM

When the gearbox and bcll housing assembly has been fitted to the vehicle the hydraulic clutch release system must be bled to expel air.

. .

NOTE: During the following procedure, keep the fluid reservoir topped-up to avoid introducing air into the system. Use only the fluid recommended in the

Lubrication chart. Use only new fluid from a sealed , container.

1. Attach a length of suitable tubing to the slave cylinder bleed screw and immerse the free end of the tube in a glass jar containing new clutch fluid.

2 . Slacken the bleed screw and depress the clutch pedal, pausing at the end of each stroke, until the fluid issuing from the tubing is free of air with the tube free end below the surface of t h e fluid in the container. Whilst holding the clutch pedal down and with the free end of the tube below the fluid, tighten the bleed screw.

Inspection

6. Clean all components with Girling cleaning fluid and allow to dry.

7. Examine the cylinder bore and piston, ensure that t h e y are smooth to the touch with no corrosion, score marks or ridges. If there is any doubt, fit ncw replacement.

8. The seal should be replaced with a new com pon e n t

Assemble

9. Smear the seal with Castrol-Girling rubber grease and the remaining internal items with Castrol-

Girling brake and clutch fluid.

10. Fit the seal, largc diameter last, to the piston.

11. Locate the conical spring, small diameter first, over the front end of the piston.

12. Smear the piston, with Castrol-Girling rubber grease and insert the assembly, spring end first, into the cylinder.

13. Fill the dust Cover with Castrol-Girling rubber grease and fit the cover to the cylinder.

CLUTCH PEDAL AND MASTER CYLINDER

ADJUSTMENT

1. The correct height for the clutch pedaI from the floor of the footwell, without a mat, to the lower edge of the pedal is 140 mm

'A'.

(5.5 in), dimension

Adjust

2. Withdraw the six screws and remove the top plate.

3 . Slacken master cylinder push-rod locknuts to provide free movement of the push-rod through the pedal trunnion.

4. Slacken the adjustment screw locknut.

5. To increase the pedal height, turn the adjustment screw anti-clockwise. T o reduce turn clockwise.

When correct tighten the locknut.

6. To adjust the master cylinder push-rod, check that

<he push-rod has free-play through thc trunnion.

7. Adjust the locknuts until the push-rod has 1,5 m m

(0.062 in) free-play between the push-rod and master cylinder. When correct tighten the loc knu ts .

8. Check that there is 6 mm (0.350 in) free movement of the pedal at the pad. If necessary readjust the push-rod.

9. Refit the top plate.

ST1535M

PRINTED IN ENGLAND BY PRINTERS (5187 37210)

- .- .

.I.

I..

Section

Number

LT77 FIVE SPEED GEARBOX

CONTENTS

LT230R TRANSFER GEARBOX

Renew front output shaft oil seals

1 can be

LT95 FOUR SPEED GEARBOX AND TRANSFER BOX

LTWLT230T MAIN GEARBOX AND TRANSFER BOX

Overhaul LT85 gearbox

LT230T TRANSFER GEARBOX

Remove from LT85 gearbox

147

PROPELLER SHAFTS

REAR DIFFERENTIAL

D UTY

REAR DIFFERENTIAL -

- Overhaul

FRONT DIFFERENTIAL

-Overhaul

Page

INTRODUCTION

This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be completed within the time stated in thc 'Repair Operation Times'.

The Manual has been produced in separate books; this allows the information to be distributed throughout the specialist arcas of the modern service facility.

A table of contents in Book 1 lists the major components and systems together with the scction and book numbers.

The cover of each book details the sections contained within that book. Each section starts with a list of operations in alphabetical order.

The title page of each book carries the part numbers required to order replacement books, binders or complete

Service Manuals. This can be done through the normal channels.

REFERENCES

References to the left- or right-hand side in the manual are made when viewing t h e vehicle from the rear. With the engine and gearbox assembly rcmovcd, the water pump end of the enginc is referred to as the front.

To reduce repetition, operations covcrcd in this manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are conccrned. - 2 s

DIMENSIONS

The dimensions quoted are to design engineering spccification. Alternative u n i t equivalents, shown in brackets following the dimensions, havc bccn converted from the original specification.

During thc pcriod of running-in from new, ccrtain adjustments may vary from t h e specification figurcs given in this

Manual. These adjustments will be re-set by t h e Distributor or Dealer at thc Aftcr Sales Service, and thercal'ter should be maintained at the figures spccified in the Manual.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential that only Land Rover parts are used.

Attention is particularly drawn to the following points concerning rcpairs and the fitting of replacement parts and accessories:

Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehiclc manufacturer's specification. Torque wrench setting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling abroad should ensure that t h e accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement may be invalidated by t h e fitting of other than Land Rover parts.

All Land Rover parts havc the full backing of the Owners Service Statement.

Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts. g?-

"---

POISONOUS SUBSTANCES

Many liquids and other substances used in motor vehicles are poisonous and should under n o circumstances be consumed and should as far as possible be kept away from open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safe!y. It 2!so oll!!iReS !he ather are2s of risk which m u t not be ignored.

This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of your local Fire Officer.

GENERAL

Petrol/gasoline vapour

I S highly flammable and in confined spaces is also very explosive and toxic.

When petroVgasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. I t can readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is potentially very dangerous.

Always have a fire extinguisher containing FOAM CO2 GAS, o r POWDER close at hand when handling or draining fuel, or when dismantling fuel systems and in areas where fuel containers are stored.

Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system.

Whenever petroVgasoline is being handled, draincd or stored, o r w h e n fuel systems are being dismantled all forms of ignition must be extinguishcd or removed, any head-lamps used must be flameproof and kept clear of spillage.

NO O N E SHOULD B E PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL!

GASOLINE WITHOUT FIRST HAVlNG H A D SPECIALIST TRAINING.

FUEL TANK DRAINING

WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST

IT IS STANDING OVER A PIT.

Draining or extracting petroligasoline from vehicle fuel tank must be carried out in a well ventilated area.

The receptacle used to contain the pctrol/gasoline must be more than adequate for t h e full amount or fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storagc area which meets the requirements of local authority regulations.

WHEN PETROL/GASOLINE HAS BEEN EXTRACTED OR DRAINED FROM A F U E L TANK THE

PRECAUTIONS GOVERNING NAKED LIGHTS AND IGNITION SOURCES S H O U L D BE MAINTAINED.

FUEL

TANK

REMOVAL

As an added precaution fuel tanks should havc a PE'I'ROL/GASOLINE VAPOUR warning label attached to them as soon as t h e y are rcmovcd from the vehicle.

FUEL TANK REPAIR

Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering the tank SAFE, by usingone of the following methods:

STEAMING: With the filler cap and tank unit removed, empty the tank. Steam thc tank for at least two hours with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any sediment and sludge n o t volatiscd by the steam, is washed out during the steaming process.

BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely i n boiling water containing a n effective alkaline degreasing agent or a dctcrgent, with the water filling and also surrounding the tank for at least two hours.

After steaming or boiling a signed and dated label to this effect should be attached to the tank.

SPECIFICATION

The Manufacturers reserve the right to vary their specifications with o r without notice, and at such times and in such manner as they think fit. Major as well as minor changes may be involved in accordance with t h e Manufacturer's policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the

Manufacturer nor the Distributor or Dealer. by whom this Manual is supplied, shall in any circumstances bc held liable for any inaccuracy or the consequences thereof.

COPY

RIGHT

Rover Limited, Service Department, Solihull, England.

...

I l l

Special

Service

Tools

The use of approvcd special scrvice tools is important. Thcy are essential if scrvicc opcrations arc t o be carricd out cfficicntly, and safely. The amount of timc which thcy save can be considcrable.

Every special tool is designcd with the closc co-operation of Land Rover Ltd., and no tool is put into production which has not been tested and approvcd by us. New tools are only introduced wherc an operation cannot be satisfactorily carried out using cxisting tools o r standard equipment.

The user is therefore assurcd that the tool is ncccssary and that it will perform accuratcly, efficiently and safely.

Special tools bullctins will be issued periodically giving details of new tools as thcy are introduced.

All orders and enquiries from the United Kingdom should be sent dircct to V. L. Churchill.

Overseas orders should be placed with the local V. L. Churchill distributor, whcrc o n e exists.

Countries whcrc thcrc is no distributor may ordcr dircct from V. L. Churchill Limited, PO Box 3,

Daventry, Northants, England N N l l 4NF.

Thc tools rccommended in this Workshop Manual are listed in a multi-language, illustrated cataloguc obtainable from

Messrs. V. L. Churchill a t thc above addrcss under publication number 221?!2!84 or from Land Rover Ltd., under part number LSM0052TC from the following address, Land Rover Publication Scrvicc, P.O. Box 534, Erdington, Birmingham,

B24 OQ5.

LT77 FIVE SPEED GEARBOX

1371

-.x,,<::

;,+:;

. : : . : . a

..._

REMOVE LT77 FIVE SPEED GEARBOX AND 230R

TRANSFER BOX

1. Install the vehicle on a ramp.

2. Disconnect the battery.

3 . Remove the gear lever knob.

4. Remove the transfer and differential lock knob.

5 . Remove the gear lever cover.

6. Remove t h e 10 mm Nyloc nut and plain washer.

Mark the gear lever spline setting and dctach the gear lever and gaiter from the splined lower gear lever.

7. Select high range to prevent the transfer gearbox selector lever fouling t h e tunnel when removing the gearbox.

8. Remove the bonnet.

9. Remove the nuts and bolts retaining the fan cowl to the engine and move the cowling forward, clear of the engine.

10. Release the transmission breather pipes, speedometer cable, and starter motor harness from clips at rear of the engine.

11. Release clamp holding heater pipes on top of engine to prevent heater inlet pipe fouling bulkhead.

12. Raise the ramp.

13. Remove the eight nuts and bolts securing the chassis cross member and using a suitable means of spreading t h e chassis, remove the cross member.

14. Place a suitable container under the transmission, remove the three drain plugs, allow the oil to drain and refit the plugs. Clean filter on the extension housing plug before refitting.

15. Remove t h e intermediate exhaust pipe and silencer section as follows:

(a)

Release the connection to the front pipe at

(b) the flange.

Release t h e connection to the rear section at the flange immediately behind the silencer.

(c)

Remove the 'U' bolt retaining the pipe to the bracket attached to the transfer box.

16. Mark the flanges for reassembly and disconnect the front propeller shaft from the transfer box.

17. Similarly, disconnect the rear propeller shaft.

18. Disconnect the speedometer cable from thc rear of the transfer box.

19. Disconnect the handbrake inner cable by removing the split pin and clevis pin.

20. Slacken t h e retaining nuts and release the handbrake outer cable from t h e bracket.

21. Remove t h e two bolts and withdraw the clutch slave cylinder from the bell housing.

22. Manufacture a cradle to the dimensions given in the drawing and attach i t to a transmission hoist.

To achieve balance of the transmission unit when mounted on the transmission hoist, it is essential that point A is situated ovcr the centre of the lifting hoist ram. Drill fixing holes B to suit hoist table.

Secure the transmission unit to the lifting bracket at point C, by means of the lower bolts retaining the transfer gearbox rear cover.

23. Remove the bottom two bolts from the transfer box rear cover and use them to attach the rear end of t h e cradle to the transfer box. Ensure that the tube in the centre of the cradle locates over the extension housing drain plug.

24. Raise the hoist just enough to take the weight of the transmission.

\ '

0-25

6.0

U v

222.0

508.0

UATERIAL A N C WELDING SPLCIFICATION

S t e e l Plate 8s 1 4 4 0 (Glade 1 or 1 4 )

Tuhr HS 4 8 8 8 ( P a r t 2 )

Arc Welding HS 5135

ST 637M

1371

LT77 FIVE SPEED GEARBOX

25. Remove the three nuts and bolts securing the transfer box L.H. and R.H. mounting brackets to the chassis.

26. Remove the nuts retaining the brackets to t h e mounting rubbers and remove the brackets.

27. Lower the hoist sufficiently to allow the transfer lever to clear the transmission tunnel aperture.

28. Disconnect t h e four-wheel drive indicator electrical lead (bullet connection).

29. Remove the cleat retaining the reverse light switch wires from the R.H. side of the gearbox.

30. Disconnect t h e wire from the reverse light switch situated at the top rear of the selector housing and rnove the harness away from the transmission.

31. Support the engine under the sump with a jack, placing timber between the jack pad and sump.

32. Remove the eleven hell housing nuts.

33. Withdraw the transmission whilst ensuring all connections to the engine and chassis are released.

Separating the transfer box from gearbox

41. Withdraw the transfer box. For LT230 transfer gear box dismantling refer to page 19. Dismantling information on LT77 gearbox, refer to page 3.

Assembling transfer box to main gearbox

42. Hoist the transfer box into position and ensuring that the loose upper dowel is fitted, assemble to main gearbox extension housing and secure with the four bolts and two nuts.

43. Fit the transfer selector housing to the main gearbox remote gear change housing with t h e four bolts. (The right hand rear bolt is longer).

44. Fit the breather pipes.

45. Fit the diffcrential lock cross shaft lever pivot bracket to the extension housing with thc two bolts.

46. Connect the cranked lever to the differential lock lever with a new split pin. (On early production connect the short link with a new ‘Nyloc’ nut).

Fitting main gearbox and transfer box to engine

47. Fit the cradle to the transmission hoist and the transmission to the cradle as described in instruction 23. Smear Hylomar on bell housing face mating with engine.

48. Locatc the gear lcver temporarily and select any gear in the main gearbox t o facilitatc entry of the primary shaft.

49. Position and raise hoist and fit t h e transmission to the engine whilst keeping wires and pipes clear to prevent trapping.

50. Secure the transmission to the engine with the eleven nuts, noting that the top R . H . nut holds a clip for the speedometer cable.

51. Position the revcrse light wires to the R.1-I. side of the main gearbox and secure with a cleat to the breather pipes.

52. Connect the reverse light wire to the switch at the top rcar of the selcctor housing.

53. Conncct the differential lock indicator wires (bullet connection).

54. Raise thc transmission to line-up with the engine and ensure that t h e transfer lever clears the tunnel aperture.

55. Fit the transfer box L.H. and R . H . mounting brackets but only partially tighten the securing nuts and bolts.

56. Loosely fit the rubber mounting nuts and lower the transmission onto t h e mountings. Fully tighten all the securing nuts and bolts.

57. Remove the supporting jack from under the engine

,...--

58. Remove the two bolts securing the cradle to the transfer box and remove the cradle and hoist.

59. Refit thc two bolts using Loctite 290 o n the threads and note that t h e L.H. bolt holds a clip for the speedometer cable.

60. Fit the slave cylinder using Hylosil on the gasket and tighten the two bolts evenly to 22 to 28 Nm (16 to 21 Ib ft).

. .

61. Fit the handbrake cable using a new split pin to secure the clevis pin. Grease the clevis and tighten the outer cable lock nuts.

62. Connect the speedometer cable.

63. Check that t h e three drain plugs are tight and remove the main gearbox and transfer box filler level plugs. Fill the main gcarbox with approximately 1,76 litres

(3

pints) of a recommended oil or until it begins to run out of the filler level hole. Fit and tighten the filler plug.

Similarly remove t h e transfer filler level plug and inject approximately 2,6 litres (4.5 pints) of recommended oil or until it runs out of the filler hole. Apply Hylosil to the threads and fit the plug and wipe away any surplus oil.

64. Line up the marks and fit the front and rear propeller shafts to the transfer box.

65. Fit the exhaust system, and evenly tighten the flange nuts and bolts. Fit the ‘U’ bolt and secure to

- the bracket.

66. Expand the chassis side members, fit the cross member and secure with the eight n u t s and bolts

(four each side).

67. Fit t h e heater pipe clamp.

68. Clip the breather pipes, specdometer cable and starter motor harness to rear of engine.

69. Fit thc fan cowl.

70. Fit t h e bonnet.

71. Fit main gear lever gaiter and lever, to previously marked spline setting. Secure with the 10 mm

‘Nyloc’ nut (with plain washer) to the correct torque.

72. Fit the cover to both gear levers.

73. Fit the gear lever knobs.

74. Connect the battery.

OVERHAUL LT77 FIVE SPEED GEARBOX

(4 cylinder petrol and diesel)

Service Tools:

18G705

18G705-1A

18G705-5 -

18G1400 - for synchromesh hub and gear cluster

18G1400-1 - Adaptor mainshaft 5th gear

MS47 -

18G47BA - Adaptor, layshaft bearing remover

18647BAX -Conversion kit

186284

18G284AAH track

1861422 -

!8G!431 -

5th gear and oi! sea! cellar replacer

Dismantle

1. Place gearbox on a bench with the transfer gearbox removed, ensuring the oil is first drained.

2. Remove t h e clutch release bearing carrier clip.

3. Remove t h e clutch release bearing and carrier.

LT77 FIVE SPEED GEARBOX (37

4. Pull the clutch release lever from the clutch release lever pivot.

5. Rcmove the bolts and washers securing the clutch release lever pivot.

6. Remove the bolts and washers securing the bell housing and remove the bell housing.

7. Remove t h e three bolts and washers retaining the gear selector housing to the fifth gear extension case. Lift the housing from the case and discard the gasket.

ST541 M I

8. Using a suitable pin punch, remove the roll pin retaining the selector yoke.

9. Push the selector shaft forward to engage a gcar, and manoeuvre the selector yoke from the shaft.

Return the selector shaft to neutral.

10. Remove the circlip which retains the mainshaft oil seal collar located at the rear of the gearbox.

LT77 FIVE SPEED GEARBOX

ST542M

11. Using tools 186705 and 186705-1A remove the oil seal collar.

ST 908M

20. Release the circlip retaining the fifth gear synchromesh assembly to the mainshaft.

21. Using tools 18G1400-1 and 18G1400 withdraw the selective washer, fifth gear synchromesh hub and cone, fifth gear (driven) and spacer from the mainshaft.

22. Remove the split roller bearing assembly from the main sh a f t .

23. Using tools 186705 and 18G705-1A remove the layshaft spacer (if fitted) and layshaft fifth gcar.

ST543M

12. Remove the ten bolts and spring washers securing the rear cover to the gearcase; withdraw t h e rear cover and discard the gasket.

13. Fit two dummy bolts (8 x 35 mm) to the casing to retain the centre plate to the main case.

14. Remove the oil seal collar ‘0’ ring from the mainshaft.

15. Withdraw the oil pump drive shaft.

16. Remove the two bolts and spring washers securing the fifth gear selector fork and bracket.

17. Withdraw the fifth gcar selector spool.

18. Withdraw the fifth gear selector fork and bracket.

19. On early models, remove circlip retaining fifth gear (driving) from the layshaft. On later models, engage reverse gear by turning selector raii anti- clockwise and pulling rearwards. Move the fifth speed synchro hub into mesh with the fifth gear.

De-stake the retaining nut securing the fifth gear iayshaft and remove nut. Select neutral by pushing selector r;3il inwards and turning clockwise; and return fifth speed synchro hub to its out of mesh position.

24. Remove the selector shaft circlip.

25. Fit suitable guide studs (measuring 8 x 60 mm) to the main gearbox case.

26. Locate t h e gearbox to a suitable stand.

27. Remove the six bolts and spring washers from the front cover. withdraw the cover and discard the gasket.

28. Remove the input shaft and layshaft selective washers from the gearcase.

29. Remove the two bolts and washers securing the locating boss for the selector shaft front spool, withdraw the locating boss.

30. Withdraw the selector plug, spring and ball from the centre plate.

' .

31. Remove the dummy bolts and carefully lift the gearcase, leaving the ccntre plate and gear assemblies in position. Discard gasket.

32. Insert two slave bolts and nuts to retain t h e centre plate to the stand; and remove the circlip, pivot pin, reverse lever and slipper pad.

33. Slide the reverse shaft rearwards and lift off the thrust washer, reverse gear and reverse gear spacer.

34. Lift off the layshaft cluster.

35. Remove the input shaft and fourth gear synchromesh cone.

LT77 FIVE SPEED GEARBOX 37

36. Rotate the fifth gear selector shaft clockwise

(viewed from above) to align the fifth gear selector pin with the slot in the centre plate.

37. Remove the mainshaft and selector fork assemblies from the centre plate.

38. Detach the selector fork assembly from the mainshaft gear cluster.

39. Remove the slave bolts from thc centre plate and lift the centre plate clear of the stand.

Front cover

40. Remove and discard the oil seal from the front cover. Do not fit a new oil seal at this stage.

Layshaft

41. Using prcss 18G705 and tool 186705-5 remove the layshaft bearings.

. .

ST545M

LT77 FIVE SPEED GEARBOX

Mainshaft

42. Remove the centre bearing circlip.

43. Using press MS47 and any suitable metal bar, remove the centre bearing, first gear bush, first gear and needle bearings and first gear synchromesh cone.

44. If a difficulty is experienced in removing the first and second gear synchromesh hub, locate underneath the sccond gcar with a suitablc tool; and extract the complete synchromcsh hub and second gear assemblies using a suitable press.

45. Using press MS47 and extension, with a support underneath the third speed gear, press the mainshaft through the pilot bcaring spacer, third and fourth synchromesh hub, third gear synchromesh cone, third gear and third gcar needle roller bearing.

First and second gear synchromesh assemblies

46. Mark the hub and sleeve to aid reassembly and remove the slipper rings from the front and rear of the first and second gear synchromesh assemblies.

47. Withdraw the slippers and hub from thc sleeve.

Third and fourth gear synchromesh assemblies

48. Mark the hub and slecve to aid reassembly and remove the slipper rings from t h e front and rear of the assembly.

49. Withdraw the slippers and hub from the sleeve.

Extension case

SO. Remove the three oil pump housing bolts, spring washers and oil pump gears.

51. Do not withdraw t h e oil pick-up pipe.

52. Remove the plug, washer and filter.

53. Invert casing and extract the oil seal.

54. Press out the ferrobestos bush from the casing.

Input shaft

55. Using tools MS47 and 18G47BA, reniovc the input shaft bearing.

56. With the aid of tools 18G284AAH and 186284, cxtract the pilot bearing track.

ST 873M

Reverse idler gear

57. Remove the circlip from the reverse idler gear.

58. Having noted their positions, remove both ncedle roller bearings and remaining circlip from the gear.

Fifth gear synchromesh assembly

59. Lever the backing plate off the fifth gear synchromesh assembly.

60. Remove the slipper rings from the front and rear of the assembly.

61. Release the slippers and slide the hub from the sleeve.

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Centre plate

62. Remove the layshaft and mainshaft bearing tracks from the centre platc and reverse pivot post.

Main gearbox casing

63. Remove the mainshaft and layshaft bearing tracks from the main casing.

64. Remove the plastic oil trough from thz front of t h e casing.

Selector rail

65. The selector rail is supplied complete with first and second selector fork, pin and fifth speed selector pin. If it is required to replace the first and second selector fork on its own, press out the fifth speed gear selector pin and remove t h e first and sccond selector fork from the selector rail.

Gear selector housing

66. Remove the roll pin and release the bias spring.

67. Remove the two adjusting screws and locknuts.

68. Remove the gear lcvcr cxtension, secured by a nut (with p h i n wash er) .

69. Remove the bolt and special lock washer to release t h e gear lever shaft from the trunnion housing.

70. Remove the four bolts and spring washers retaining the gear lever housing to the selector housing. Lift off the housing and discard the gasket.

~ ~ FI 7 S 7 P EE D GEARBOX

137

Gear selector housing

(Not illustrated)

(a) Rcmove the gear lever gaiter and three bolts holding the gear lever retaining plate and anti-vibration pad.

(b) Remove gear lever from the gear lcvcr housing.

(c) Removc the four bolts and spring washers retaining the gcar levcr housing to the selector housing. Lift off the housing and discard the gasket.

(d) Remove the bolts and washers retaining the fifth gcar plunger assembly. Care must be taken not to lose the shims located on the plunger assembly casting.

(e) Withdraw the asscmbly from the selector housing and label components for identification o n reassembly.

71. Rcmove thc bolts and washcrs retaining the reverse gear plunger assembly. Care must be taken not to lose the shims located on the assembly casting. Detach from the selcctor housing and label components for identification.

72. Remove t h e locating bolt from the housing for nylon bush. Pull the selector shaft rearwards and remove t h e trunnion housing.

73. Release the circlip and detach the nylon insert from the trunnion housing.

74. Invert the gear selector housing and removc the fifth gear spool retainer bolts and spring washers.

Lift off the fifth gear spool retainer.

75. Remove the large blanking plug at the rear of the housing .

76. Remove the reverse switch blanking plug.

77. Place the gear selector housing into protected vice jaws, using a suitable pin punch, drift out the selector yoke roll pin. Push t h e selector shaft forwards and remove the selector yoke. Remove housing from vice.

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ST548M 77

78. Remove the selector yoke roller circlip and withdraw the pin and rollers.

79. Withdraw the gear selector housing shaft out through the large blanking plug orifice.

80. Remove and discard the gear selector shaft ‘0’ ring.

LT77 FIVE SPEED GEARBOX

Fifth gear plunger assembly -

81. Remove the plug, long spring and detent ball from the fifth gear plunger.

82. Remove the circlip which retains the fifth gear plunger, pull out plunger and short spring. Keep all parts labelled and separated from the reverse plungerassembly.

ST549M

Reverse gear plunger assembly

83. Remove the plug, long spring and detent ball from the reverse gear plunger assembly.

84. Detach the circlip which retains the reverse gear plunger, pull o u t the plunger followed by the short spring. Labcl all parts and keep separate from the fifth gear plunger assembly.

86. Inspect all gear teeth for chipped or broken teeth, o r showing signs of excessive wear. Inspect all spline teeth on the synchromesh assemblies. If there is evidence of chipping or excessive wear, install new parts on reassembly. Check all slippers and slipper rings for wear or breakage. Replace with new parts if necessary.

87. Inspect all circlip grooves for burred edges. If rough or burred, remove condition carefully using a fine file.

58. Ensure all oil outlets are clear of sludge or contamination especially the mainshaft oil ways.

Clean with compressed air observing the necessary safety requirements.

89. During the rebuild operation, it is recommended that new roller and needle bearings are fitted.

ASSEMBLY

Layshaft

90. Using tools MS47 and a suitable tube, fit new bearing cones to the layshaft.

Synchromesh assemblies

91. With the outer sleeve held, a push-through load applied to the outer face of the synchromesh hub should register 8,2 to 10 kgf m (18 to 22 Ibf ft) t o overcome the spring detent i n either direction.

92. Assemble the first and second synchromesh asscmbly by locating the shorter splincd face towards the second gear.

ST550M

Cleaning and inspection

85. Clean gearcase thoroughly using a suitablc solvent. Inspect case for cracks, stripped threads in the various bolt holes, and machined mating surfaces for burrs, nicks or any condition that would render the gearcase unfit for further service. If threads are stripped, install Helicoil, or equivalent inserts.

ST551M

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LT77 FIVE SPEED GEARBOX I37 I

LT77 FIVE SPEED GEARBOX

93. Refit the slippers and locate the slipper rings to each side of the assembly, ensuring that the hooked ends of both slipper rings are located in the same slipper; but running in opposite directions and finishing against the other t w o slippers.

ST552M

94. Assemble the third and fourth synchromesh assembly and ensure the hooked ends are located in the same slipper; and run in opposing directions and finally locate against the other two slippers.

95. Refit the fifth synchromesh hub assembly again ensuring the hookcd ends of the rings are located in the same slipper, but running in opposite dircctions. Fit t h e backplate onto the rear of the synchromcsh hub asscmbly. Ensure the tag on the backplate locates in the slot on the hub.

96. Check the wear between all the synchromesh cones and gears by pushing the conc against the gear and measuring the gap between the gear and cone. The minimum clearance is 0,64 mm

(0.025 in). If this clearance is not met, f i t new synchromesh cones.

ST553M

First gear bush end-float

97. Manufacture a spacer to the dimensions provided in the illustration, this will represent a slave bearing .

53-0mm

0.10

38.3

+0-005

-0-000 16-52 mm

0-005

- o*ooo

ST531M

98. Lubricatc the second gear needle bearing with a light oil and fit the bearing, second gear and synchromcsh cone to the mainshaft. It should be noted that the second gear synchromesh cone has larger slipper slots than the other synchromesh cones.

99. Fit thc first and second synchromesh hub assembly with the selcctor fork annulus to the rear of the mainshaft.

100. Fit the first gear bush and slavc bcaring spacer and a new circlip to the mainshaft. When fitting the circlip, care must be taken to ensure it is not opened (stretched) beyond the minimum necessary to pass over t h e shaft.

101. Press the slavc bearing spacer back against the circlip to allow the bush maximum cnd-float.

Measure the clearance between the rear of thc first gear bush and front face of the slave bearing spacer with a feeler gauge. The clearance should be within 0,005 to 0,055 mm. The first gear bush is available with collars of diffcrcnt thickness.

Select a bush with a collar to givc t h e required end-float. The bush must be free to rotate easily with the required cnd-float.

102. Remove the circlip, slave bearing spacer and first gear bush from the mainshaft.

103. First gear bushcs are available in the following sizes:

Part N o . Thickness (mm)

FRCS243 40,16 - 40,21

FRC5244 40,21 - 40,26

FRC5245 40,26 - 40,31

FRC5246 40,31 - 40,36

FRC5247 40,36 - 40,41

104. Having selected a suitable first gear bush, lubricate the needle bearing and fit to the first gear.

105. Fit the selected bush to t h e first gear and placc

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L I I L 1 1 1 3 1 gear assembly to the mainshaft.

106. Using tools MS47, 18G47BA and 18G47BA-X refit the centre bearing and circlip to the mainshaft.

107. Invert the mainshaft, lubricatc the third gear needle roller bearing with light oil, fit to the front end of the mainshaft.

~ ~ FIVE S PEED G E A R BOX

137

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108. Fit the third gear to the mainshaft; and locate the third gear synchromesh cone to the third gear.

109. Fit the thirdlfourth synchromesh assembly (with the longer box of the synchromesh hub to the front of the gearbox) to the mainshaft.

110. Fit the spaccr and bearing to the front of the mainshaft.

Input shaft

111. Using tool MS47 and any suitable tube, refit a new pilot bearing track to the input shaft.

112. Fit the input shaft bearing using tools MS47,

18G47BA and 18G47BA-X.

Reverse Gear and Shaft

113. Fit a new circlip to the rear of the reverse idler gear, ensuring that the circlip is not stretched

I beyond the minimum necessary to pass over the shaft.

114. Lubricate with light oil and fit both needle roller bearings. Fit the shorter necdle bearing to the rear of the reverse idler gear.

115. Fit a new circlip to the front of the reverse idler gear.

Extension case

116. Using a suitable press, fit a new fcrrobcstos bush to the case, ensuring t h c two drain holes are towards thc bottom of the case.

ST554M h

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117. With the aid of tool 18G1422, fit a new oil seal to the rear of the extension case. Ensure the seal lips are towards the ferrobestos bush. Lubricate thc seal lips with a suitable SAE 140 oil.

118. Assemble and fit the fibre oil pump gears to the oil pump cover, whilst ensuring the centre rotor squared drive faces t h e layshaft.

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ST555M k z 2

117

119. Fit the three bolts and spring washers to secure the oil pump covcr; and tighten to thc specified torque.

120. Ascertain that the oil pick up pipe is free of contamination or blockage.

121. Fit a new oil filter, fibre gasket and tighten plug to the specified torquc.

Centre plate

122. Fit the ccntre platc to a suitable stand and secure with two slave bolts.

123. Place the new mainshaft and layshaft bearing tracks to the centre plate.

124. Lightly lubricate the selector shaft with a light oil.

125. Take the selector shaft complete with the first and second selector fork, front spool and third and fourth selector fork; engage both selector forks in their respective synchromesh slccvcs on thc mainshaft, simultaneously engaging the sclcctor shaft and mainshaft assemblies

In the centre plate, whilst rotating the fifth gear selector pin to align with the slot in the centre plate.

126. Fit the layshaft to the centre plate.

127. Rotate the wler!or shaft and spoo! to emb!e !he reverse crossover lever forks to correctly align to the reverse pivot shaft. Reposition the selector shaft and locate the lever between the fork on the reverse gear pivot shaft. Insert pivot pin and fit a new circlip, ensuring that it is not opened beyond the minimum necessary to pass over the shaft.

LT77 FIVE SPEED GEARBOX

126

128. Fit t h e slipper pad to the reverse lever. If a new reverse lever pivot shaft has been fittcd, it will be necessary to ascertain that its radial location is consistent with the reverse pad slipper engagementklearance. The radial location is determined during initial assembly.

130. Prior to assembly lubricate the detent ball and spring with light oil, and fit to the top of centre plate. Smear Hylomar PL32 or Loctite 290 to the plug threads and screw the plug flush with the case. Stake the plug to prevcnt rotation using a suitable centre punch. Release the slave bolts.

131. Locate the fourth gear synchromesh cone to the third/fourth synchromesh assembly.

132. Fit the input shaft to the mainshaft.

133. Fit the reverse gear spacer to t h c reverse gear shaft.

134. Fit a new gasket to the centre plate.

Main gearbox casing

135. Insert a new plastic oil trough to the back of the main gearbox casing, ensuring the open trough faces the top of the case.

136. Carefully lower the gearcase into position over t h e gear assemblies. DO N O T USE FORCE.

This operation can be assisted by the use of two 8 x 100 mm guide studs. Ensure the centre plate dowels and selector shaft arc engaged in their respective locations.

137. Fit the layshaft and input shaft bearing outer tracks.

138. Using 8 x 35 mm slave bolts and plain washers to prevent damaging the rear face of the centre plate, evenly draw the gcarcase into position on the plate.

139. Fit the locating shaft front spool to the top of the gearcase using Hylomar PL32 to seal between the spool and gearcase. Smear Loctite 290 or

Hylomar PL32 to the bolt threads, tighten bolts and spring washers to the specified torque.

140. Manufacture a layshaft support plate and plain washer to the dimensions provided in the illustration.

ST557M

'129

129. Fit the reverse gear spacer and reverse gear assembly, locating the slipper pad lip to t h e reverse gear groove. Engage the reverse gear shaft from the underside of the centre plate, ensuring the roll pin is aligned with the slot in thc centre plate casing.

ST1118M

141. The layshaft support plate is fitted using two 8 x

25 mm bolts and washers to the front of the gearbox, with the plain washer situated between the support plate and layshaft. The plate also retains the input shaft bearing outer track.

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~ ~ F I 7 E 7 X

137

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142. O n early models: With the aid of a suitable press, fit the fifth gear, collar and new circlip to the layshaft.

Later models: Fit the fifth gear to the layshaft using a suitable press and loosely fit a NEW special n u t . T o tighten the nut, hold t h e gearbox firmly in a Vice and if necessary use a flange holding wrench to restrain the gearbox. Tighten the nut to 204 to 231 Nm (150 to 170 Ib ft). To prevent damage to the adjacent bearings when deforming the nut locking collar, support the fifth gear with a block of timber. Using a round nose punch carefully form the collar into the layshaft grooves, as illustrated.

. ...

143. Locate assembly horizontally in a vice or suitablc jig.

144. Fit thc fifth speed washer, roller bearing, gear and cone to the mainshaft.

145. Press fit fifth gear synchromesh hub assembly using tool 1861431. Fit a dummy spacer with an oversize bore to ascertain thc correct spacer to provide the specified clearance on the fifth gear.

When fitting, care must be taken to ensure the hub assembly and selective spacer are NOT pushed too far on the mainshaft. Only fit with sufficient clearance to allow the circlip to engage

ST a m u

146. Measure t h e clearance between the front spaccr and fifth gear (driven), which should be between

0,005 and 0,055 mm. Select the appropriate spacer to provide the aforementioned clearance.

Part No. Thickness Part No. Thickness

("1 (n1m)

FRC5284 5,lO

FRC5286 5,16

FRC5288 5,22

FRC5290 5,28

FRC5292 5,34

FRC5294 5,40

FRC5296 5,46

FRC5298 5,52

FRC5300 5 3 8

FRC5302 5,64

147. Fit the correct selective spacer and new circlip.

Mainshaft and layshaft end-tloat

148. Measure and adjust the mainshaft and layshaft end-float as necessary. Remove the layshaft support platc from the front o f the gearbox.

Part No. Thickness Part No. Thickness

("> (")

FRC4327

FRC4329

FRC433 1

FRC4333

FRC4335

FRC4337

FRC4339

FRC4341

FRC4343

FRC4345

FRC4347

1 3 1

1 3 7

1,63

1,69

1,75

1,81

1 3 7

1,93

1,99

2,05

2,11

FRC4349

FRC435 1

FRC4353

FR C43 5 5

FRC4357

FRC4359

FRC4361

FRC4363

FRC4365

FRC4367

FRC4369

2,17

2,23

2,29

2,35

2,41

2,47

2,53

2,59

2,65

2,71

2,77

149. When ascertaining thc mainshaft end-float care must be taken when checking the dial gauge readings 10 ensure that the end-float only, as distinct from side movement, is recorded. To overcome the difficulty in differentiating betwecn end-float and side movement, wrap approximately ten tums of masking tape around the plain portion of the input shaft below the splines.

Ascertain that the rise and faii of the input shaft is not restricted by the tape.

150. Place a mainshaft and layshaft spacer of nominal thickness 1.02 mm o n the mainshaft and layshaft bearing tracks, fit the front cover and gasket tighten bolts and spring washers to the specified torque.

151. Invert the gearbox on the stand. Rotate the mainshaft to correctly seat the bearing.

LT"7 FIVE SPEED GEARBOX

152. Place a suitable ball bearing in the mainshaft centre and mount the dial gauge on the gearcase with the stylus resting on the ball bearing centre.

Zero the gauge.

153. Check the end-float by a 'push-pull' action to the

154 mainshaft. The required mainshaft end-float measurement should be between 0,06 to 0,Ol mm with no pre-load.

Spacer thickness required equals; Nominal thickness of spacer, plus end-float obtained.

Remove t h e dial gauge and ball bearing.

155 Rotate the layshaft to correctly seat the bearing.

Place a suitable ball bearing in the layshaft centre and mount the dial gauge on the gearcase, with the stylus resting on the ball bearing centre. Zero the gauge.

I I ll Ill

158. Fit a new oil seal to the front cover, ensuring the seal lips face towards the gearbox. Lubricate the scal lips with

SAE

140 gear oil.

159. Mask the splines with masking tape to protect the oil seal. refit the front cover and remove the spline masking tape.

160. Refit the bolts and spring washers having used

Hylomar PL32 or Loctitc 290 on the bolt threads.

Tighten to thc specified torque.

161. Remove gearbox from the stand and place suitably supported on the bench. Remove the guide studs fitted to the centre plate.

162. Select reverse gear by turning the selector rail anti-clockwise and pulling rearwards. Move the fifth speed synchromesh hub into mesh with the fifth gear. Tighten the staked nut onto the fifth gear layshaft to the specified torque. Stake the nut with a suitable ounch to secure. Select neutral bv pushing selector rail inwards and turning clockwise, thereby returning the fifth speed synchromesh hub to its out of mesh position.

Fifth gear selector fork assembly

163. Fit the fifth speed selector fork and bracket to the fifth gear synchromesh hub assembly, cnsuring that the largest groove lip is facing the rear of the gearbox.

164. Fit the fifth gear spool to the selector shaft, rotate and engage t h e selector fork into the groovc. It should be noted that the longer shoulder of thc spool is fitted towards the front of the gearbox.

165. Fit t h e fifth speed sclector fork brackct bolts and spring washers. Tighten to specified torque.

With the aid of levers approximately 23 cm long; to prevent component damage, check the end- float by a gentle 'push-lift' action to the layshaft.

The required layshaft setting is:

0,025 mm end-float

0,025 mm preload.

Spacer thickness required equals; nominal thickness of spacer, plus end-float obtained.

Remove the gauge and ball bearing.

157. Remove the front cover. Having ascertained the mainshaft and layshaft end-float,-fit the mainshaft and layshaft spacers of the appropriate thickness to the mainshaft and layshaft bearing tracks.

Selective spacers are available in a range of sizes to meet the aforementioned clearance limits.

Part No. Thickness Part No. Thickness

(") (")

TKC4633 1,69

TKC4635 1,75

TKC4637 1.81

TKC4639 1187

TKC4641 1,93

TKC4643 1,99

TKC464S 2,05

TKC4647 2,11

TKC4649 2,17

TKC4651 2,23

TKC46.53 2.29

TKC4655 2135

TKC4657 2,41

TKC4659 2,47

TKC4661 2,53

TKC4663 2,59

164

165

ST56,M

166. Fit a new circlip to the selector shaft ensuring that it is not expanded beyond the minimum necessary to obtain entry.

167. Remove the six dummy bolts securing the centre plate to the naiii casiiig.

168. Position thc gearbox assembly horizontally and fit the oil pump shaft to the pump.

Extension case

169. Fit a new gasket to the centre plate.

170. Rotate the oil pump to align with the oil pump drive shaft. e .

LT77 FIVE SPEED GEARBOX 37

c:;;:p$ 171. Carefully fit the extension case ensuring that the oil pump shaft engages the layshaft.

172. Fit the extcnsion case bolts and spring washers;

. . tighten to specified torque.

173. Using a large screwdriver, ease the selector shaft forwards to selcct a gear. It may be found necessary to rotate the mainshaft to ease gear selection.

174. Fit the selector yoke to the selector shaft and secure with a new roll pin. Pull selector shaft rearwards to select a neutral position.

175. Cover t h e mainshaft splines with masking tape and fit a new oil seal collar ‘0’ masking tape.

176. Using tool 1861431 fit the oil seal collar to the mainshaft, ensuring t h e collar is NOT pushed too far on the shaft, fit only with sufficient clearance to allow the circlip to engage in its groove.

177. Fit a new gasket to the top of the fifth gear

~ extension case and fit the gear change housing by engaging male selector yoke with the female yoke. Align the housing locating dowels and refit the housing. Secure with the three bolts and washers; and tighten to the specified torque.

Bell housing

178. Locate the bell housing to the dowels and fit the two long bolts (12 x 45 mm) with spring and plain washers to the dowel positions. Thc remaining four bolts (12 x 30 mm) are fitted with spring washers only. Tighten to the specified torque.

ST562M

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178

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179. Fit the clutch release lever pivot and securc with t h e bolts and spring washers. Tighten to the specified torque.

180. Prior to reassembly, lubricate t h e following with a thin film of molybdcnum disulphide grease:

(a) Clutch release lever fulcrum pivot socket.

(b) The clutch release lever slipper pad pins and the faces of cach slippcr pad.

181. Refit the slipper pads to the clutch release lever and locate the lever socket to the clutch release lever pivot.

182. Lubricate the inner face of thc clutch release bearing carrier with molybdenum disulphide grease and fit to the front cover spigot, locating the clutch release lever slipper pads to the carrier recesses.

183. Fit a new nylon clutch release carrier clip.

184. Refit the gearbox oil level plug, and tighten to the specified torque.

185. Refit the gearbox oil drain plug and fit ncw fibre washer. Tighten plug to specified torque.

Reverse gear plunger assembly

186. Lubricate the short spring and plunger with BP

Energrease L2 or similar prior to assembly.

187. Fit the short spring into the plunger base and slide the assembly into the rcvcrse gear plunger housing. Fit a new circlip to retain t h e plunger.

Ensure the spring is not trapped, the detent groove should be fully visible down the detent hole.

188. Lubricate the detent ball with light oil and fit into its bore.

189. Refit the long spring and plug, coat the plug threads with Loctite 290 or Hylomar PL32, and tighten to the specified torque.

The following instructions (190 to 21 I) relate to the early model gearbox with

a

spring-loaded plunger for fifth gear selection.

Fifth gear plunger assembly

190. Lubricate the short spring and plunger with BP

Energrcase L2 or similar, prior to assembly.

191. Fit t h e short spring i n t h c plunger base and slide the assembly into the fifth gear plunger housing.

Fit a new circlip to retain the plunger. Ensure the spring is not trapped, t h e dctent groove should be fully visiblc down the detent hole.

192. Lubricate the dctent ball with light oil and fit into its bore.

193. Refit the long spring and plug, coat the plug threads with Loctite 290 or Hylomar PL32, tighten to the specified torque.

Gear selector housing -Early models

194. Refit t h e gear selector rollers, pin and new circlip ensuring circlip is not expanded beyond minimum necessary to obtain entry.

195. Lubricate the gear selector housing shaft with light oil and fit a new ‘0’

LT77 FIVE SPEED GEARBOX

196. Insert shaft through the large blanking plug orifice, ensuring the shaft indent is uppermost.

197. Place the gear selector housing into protected vice jaws and fit the selector yoke to the shaft, using a suitable pin punch and new roll pin. Remove the housing assembly from the vice on completion.

198. Fit the reverse switch and large blanking plugs.

Coat plug threads with Loctite 290 and tighten to t h e specified torque.

199. Refit the fifth gear spool retainer, coat the bolt threads with Loctite 290, and tighten the bolts and washers to the specified torque.

200. Fit a new nylon insert into the trunnion housing and secure with a new circlip.

201. Invert the gear sclector housing and fit the trunnion housing to the selector shaft, ensuring the locating bolt aligns with the shaft indent. Coat the bolt threads with Loctite 290. Tighten bolt to the specified torque.

202. Fit a new gear lever housing gasket and fit the gear lever housing, spring washers and bolts.

Tighten bolts to the specified torque.

203. Coat the upper and lower balls of the gear lever shaft with BP Energrease L2 or similar. Push lever into the trunnion nylon bush.

204. Place new vibration pad over the gear lever and fit the gear lever retaining plate. Refit the three shouldered bolts and tighten to the specified torque.

205. Refit the gear lever gaiter and attach the gear lever extension. Then carry out the following procedure to ensure a clearance of 0,3 to 0,9 mm between the gear lever yoke and stops.

206. Select first or second gear. It may be necessary to rotate the mainshaft whilst manipulating the gcar lever.

297. Locate tne reverse gear piunger on the right hand side viewed from the rear, giving sufficient load on the trunnion to eliminate side play. Whilst maintaining a light finger pressure, measure the clearance between the plunger assembly casting and gear selector casting. Add 0,6 mm to the measured figure and select suitable thickness shims to equal the total.

208. Remove the reverse plunger assembly, fit the required thickness shim(s) refit the plunger assembly, spring washers and bolts. ‘Tighten bolts to the specified torque.

209. Select third or fourth gear.

210. Locate the fifth gear plunger on the left hand sidc viewed from the rear, giving Sufficient load o n the trunnion to eliminate sideplay. Whilst maintaining a light finger pressure, measure the clearance between the plunger assembly casting and gear selector casting. Add 0,6 nim to the measured figure and select suitable thickness shims to equal the total.

211. Remove the fifth gear plunger assembly and fit the required shim(s), refit the plunger assembly, spring washers and bolts. Tighten bolts to the specified torque.

LT77 FIVE SPEED GEARBOX

.,..

,.-

The latest model gearbox employs a spring-loaded biased gear change lever assembly and the following instructions (212 to 236) include the fitting and adjustment of this arrangement.

Gear selector housing

212. Refit the gear selector rollers, pin and new circlip ensuring circlip is not expanded beyond minimum necessary to obtain entry.

213. Lubricate t h e gear selector housing shaft with light oil and fit a new ‘0’

214. Insert shaft through the large blanking plug orifice, ensuring the shaft indent is uppermost.

215. Place the gear selector housing into protected vice jaws and fit the selector yoke to the shaft, using a suitable pin punch and new roll pin. Remove the housing assembly from the vice on completion.

216. Fit the reverse switch and large blanking plugs.

Coal plug threads with Loctitc 290 and tighten to the specified torque.

217. Refit the fifth gear spool retainer and tighten the bolts and washer 7 Nm (5 Ibf ft) and fit a new nylon insert into t h e trunnion housing and secure with a n e w circlip.

218. Invert the gear selector housing and fit the trunnion housing to the sclector shart, ensuring the locating bolt aligns with the shaft indent. Coat the bolt threads with Loctite 290. Tighten bolt to the specified torque.

219. Fit a new gear lever gasket and locate the gear lever housing, spring washers and bolts. Tighten bolts to the specified torque.

220. Fit the two bias spring adjustment screws and lock nuts.

221. Place the bias spring in position with the spring legs either side of the gear lever housing and retain with a roll-pin.

222. Coat the upper and lower spheres of the gear lever shaft with Duckhams Q.5848 or Shell

Alvania R I and locate the lever in t h e gearbox and retain with the bolt and special lock washer.

223. Using a screw driver lift the bias spring legs over the gear lever crosspins. Do not overstress the spring legs. Refit the main gear lever with the gaiter. Align the marks made when dismantling.

Tightcn the 10 mm ‘Nyloc’ n u t .

224. Select first or second gear. It may bc necessary to rotate the mainshaft whilst manipulating the gear lever.

225. Locate the reverse gear plunger assembly on the right hand side viewed from rear, giving sufficient load on the trunnion to eliminate side play. Whilst maintaining a light finger pressure, measure the c!e2!2r?ce between the p!unger assemb!y casting and gear selector casting. Add 0,6 n i m ’ t o the measured figure and select suitable thickness shims to equal the total.

226. Remove the reverse plunger assembly, fit the required thickness shim(s) and refit the plunger assembly, spring washers and bolts. Tighten to the specified torque.

227. Fit the fifth gear stop o n the left hand side viewed from the rear, giving sufficient load on the trunnion to eliminate side play. Whilst maintaining a light finger pressure, measure the clearance between t h e plunger assembly casting and gear selector casting. Add 0,6 m m to the measured figurc and select suitable thickness shims to equal the total.

228. Remove the fifth gear stop, fit the required thickness shim(s). Refit the gear stop assembly, spring washers and bolts. Tighten bolts to the specified torque.

229. To adjust the bias springs with the unit completely assembled, engage either third or fourth gear.

230. Adjust the two adjusting screws until both legs of the spring are approximately 0,5 mm clear of the cross-pin in the gear lever. This should allow a certain amount of radial movcmcnt of the gear lever without the cross-pin contacting either of thc spring legs.

231. Apply a slight load to t h e gear lever knob in a left hand dircction to position the gear lever at one extreme of the radial play. Adjust the right hand adjusting screw downwards until the right hand spring Icg just makes contact with the cross-pin o n the right hand side.

232. Repeat instruction 229 in the opposite direction.

233. At this stage, radial play will still be present, but at the other extreme the cross-pin should just

234. make contact with the spring leg on the other side. r

_..._.. equal ~ m ~ i i i i i ~ the radial play is just eliminated. Tighten lockn u ts.

235. Return gear lever to neutral position and rock across the gate several times. The gear lever should return to the third and fourth gate. If not, repeat the aforcmentioned procedure.

236. Fit the rubber gaiter and secure with a strap.

LT230R TRANSFER GEARBOX

LT 230 R TRANSFER BOX

The following operations can be carried out with the gearbox in the vehicle. For ease of working, the vehicle should be raised on a ramp or placed over a pit. Also, the battery should be disconnected for safety.

RENEW SPEEDOMETER DRIVE PINION

1. Raise the vehicle on a ramp.

2. Remove the speedomcter drive clamp and nut and withdraw the cable.

3. Prise out t h e drive pinion assembly.

4. Push in a new assembly and fit the speedometer cable and secure with the clamp and nut.

RENEW REAR OUTPUT SHAFT OIL SEAL

Special tool:

18G1422

1. Disconnect the battery for safety.

2. Disconnect the rear propshaft from the output flange.

3. Remove thc brake drum retaining screws and withdraw the drum.

4. Remove the two back plate bolts that also retain thc oil catcher and remove the catcher.

NOTE: An hexagonal type socket should be used for these bolts.

5 . Remove the output shaft nut and washer and withdraw the flange.

6. Using thc slot provided, lever off the dust cover.

7. Prise out the output shaft oil seal(s).

8. Using special tool 1861422 fit the doublc-lipped oil seal, open side inwards, with the seal in contact with the bearing circlip, taking care not to touch the seal lips.

NOTE: The double-lipped oil seal supersedes the two oil seals used on early production.

9. Fit the dust cover.

10. Lubricate the surface of the flange which runs in the seal and carefully fit the flange.

NOTE: To renew the flange bolts first remove the circlip before fitting the flange.

11. Secure the flange with the nut and washer and

12. tighten to 146 to 179 N m (108 to 132 Ib ft).

Fit oii catchei to the “u& using si~icoiie rubber sealant and secure with the two back plate bolts (with plain washers).

13. Fit the brake drum and retain with the two screws.

14. Reconnect t h e propeller shaft.

RENEW FRONT OUTPUT SHAFT OIL SEAL

Special tool:

18G1422

1. Disconnect the front propeller shaft from the flange and move to one side.

2. Remove the output shaft nut and washer and withdraw the flange.

3. Remove the oil seal shield.

4. Prise out the oil seal(s).

NOTE: The double-lipped oil seal supersedes the two oil seals used on early production.

5. Using special oil seal replacer tool 1863422 fit the double-lipped oil seal, open side inwards, with the seal in contact with t h e bearing circlip, taking care not to touch the scal lip.

6. Lubricate the running surface of t h e flange and fit it together with the oil seal shield.

7. Secure the flange with t h e nut and washer and tighten to 146 to 179 Nm (108 to 132 Ib ft).

S. Refit the propeller shaft.

REMOVE INTERMEDIATE SHAFT AND GEARS

Service tool:

R0605862

1. Drain the transfer gearbox oil.

2. Disconnect t h e rear propshaft from the output flange.

3. Remove the two screws and withdraw t h e brake drum.

4. Remove the four bolts securing the brake back plate and withdraw the back plate and oil catcher.

NOTE: An hexagonal type socket should be used for these bolts. g-2

5 . Remove the intcrmediatc shaft keeper plate,

-.- retained by a single bolt.

6. Remove the ten bolts and remove the bottom cover plate.

7. Using service tool R0605862 withdraw the intermediate shaft whilst holding the gear cluster.

Collect the bearings and thrust washers from both ends of the cluster.

8. Remove the two ‘0’ rings, one from the shaft, the other from the casing.

Fit intermediate shaft gears

9. Fit the ‘0’ ring to thc intermediate shaft. i0. Fit t h e -0‘ of the transfer case.

11. Lubricate thrust washers, bearings, shaft and spacer.

12. Fit needle bearings with spacer interposed.

13. Fit front thrust washer to slot in transfer case (plain side to case).

14. Locate gear assembly partially into the transfer case so that i t rests o n the front thrust washer.

6.’.

N’

_..._

X=>,,..j

1 .

_..

. . . ..

':., ,.

15. Locate rear thrust washer (plain side uppermost) into slot in transfer case.

16. Gently push gear assembly into mesh.

17. Using a screwdriver through the intermediate shaft hole guide thc locating tab on the rear thrust washer into the slot provided in the transfer case.

18. Align gear and thrust assembly and slide the intermediate shaft into the transfer box from the rear.

19. Align the shaft so that the lock plate in the end is on top.

20. Apply Loctite 290 to the lock plate bolt threads.

Locate lock plate into position and fit securing bolt

(with spring washer).

21. Lever the gear.assembly to one side and measure the end-float with feeler gauges. This should be between 0,08 and 0,35 mm (0.003 and 0.014 in).

22. Grease and fit the bottom cover joint washer.

23. Apply Loctite 290 to the ten bolts and evenly tighten to 22 to 28 N m (16 to 21 Ibf ft).

24, Fit the oil catcher to the brake plate, using silicone rubber sealant and secure the backplate with the four bolts. The t w o bolts securing the oil catcher are fitted with plain washers.

25. Fit the brake drum and retain with the two screws.

26. Connect the rear prop shaft.

27. Refill t h e transfer box with the correct oil.

LT230R TRANSFER GEARBOX

137 I

":.

, :'

L.:

LT230R TRANSFER GEARBOX

OVERHAUL LT230R TRANSFER GEARBOX

Service tools:

RO 605862

18G1273 - remover

18G1205 -

18G257

18G1422

Circlip pliers

18G1423 - Stake nut remover

MS47

18G47BB/1- Collars

18G47BB/3 - Button

18G47BB/2 -

1801424

18G47-7

LST 47-1 -

REMOVE ASSEMBLIES FOR OVERHAUL

(Instructions 1 to 33)

1. Having removed the complete gearbox and transfer box assembly. The transfer box is separated from the gearbox on the work bench.

NOTE: To facilitate removal of various items on the work bench, obtain suitable wooden blocks to enable the transfer box to be turned and propped up as required.

Hand brake linkage removal

2. Remove the split pin and clevis pin to release the handbrake linkage from the brake operating lever.

3 . Remove the two bolts (with spring washers) securing t h e rear end of the handbrake mounting

4. bracket to the casing, the lower bolt is shorter.

Remove the two bolts (with spring washers and distance pieces) securing the front sidc of the handbrake mounting bracket and remove from the transfer box.

6 . Disconnect the bottom of the high/low connecting rod from the high/low operating arm by removing the split pin and clevis pin.

7. Remove the plastic bushes from the operating arm.

8. Remove the gearchange housing complete with linkage.

Transfer box mounting removal

5 . Remove the bolts retaining the right hand rubber mounting plate.

GENERAL ARRANGEMENT OF LT230R TRANSFER GEARBOX

~ ~ 2 T 3 0 ~ G EARBOX

137 I

LT230R TRANSFER GEARBOX

GENERAL ARRANGEMENT OF TRANSFER GEARCHANGE HOUSING

1. Main selcctor lever.

2. Transfer gear selector assembly.

3. Differential lock selector assembly.

1 f;

ST886M P

‘ J

LT230R TRANSFER GEARBOX

1371

Transmission brake removal

9. Remove the two countersunk brake drum retaining screws and pull off the drum.

10. Removc t h e four bolts securing the brake backplate, two of these also retain the oil catcher.

NOTE: An hexagonal type socket should be used for these bolts.

Bottom cover removal

11. Hemove the ten bolts retaining the bottom cover.

Intermediate shaft removal

12. Remove the shaft lock plate retained by a single bolt at the rear face of the transfer box.

Power take off cover removal

17. Remove the four bolts retaining the circular

P.T.O. cover and the speedometer cable clip plate.

18. Removc the gasket.

NOTE: The other two bolts were removed with the gearbox assembly cradle.

13. Withdraw the intermediate shaft, using a screw driver in t h e slotted end. Where the shaft cannot be easily withdrawn use extractor R0605862.

14. Lift out the intermediate gear cluster, roller bearings and spacer.

15. Remove the thrust washers.

16. Remove the '0' ring from the intermediate shaft and the transfer box case.

ST 1

(371

~ ~ 2 3 0 ~ G EA RBOX

Input gear removal

19. Remove the two countersunk screws and release the mainshaft bearing housing.

20. Remove the gasket.

21. Remove the input gear assembly.

22. Prise out and discard the oil seal at the front of the transfer case using service tool 1861271.

23. Drift out the input gear front bearing track.

30. Remove the centre differential unit with the selector shaft/fork assembly.

Highhow selector housing removal

24. Remove the six bolts to release the selector housing.

25. Remove the gasket.

ST1165M

Front output shaft housing removal

26. Slacken the square headed set screw securing the yoke to the high/low selector shaft inside t h e highhow selector housing aperture.

27. If necessary use a screw driver to move the selector shaft rearwards and allow thc yoke to be lifted out.

28. Remove the eight bolts to release the front output shaft housing assembly. The upper middle bolt is longer.

NOTE: The ‘radial’ dowel in the transfer box face should not be disturbed.

Centre differential removal

29. Remove the high/low selector shaft detent plug, spring and ball.

NOTE: The ball may be more easily retrieved from inside the transfer case after the selector shaft is taken out.

Rear output shaft housing assembly removal

31. Remove t h e six screws to relcase the housing. The upper screw is longer.

32. Remove the gasket. r l .

..bi’

NOTE: Removal of the above housing will reveal the centre differential rear bearing track in the transfer box casing. Before drifting out, either unscrew the two studs and radial dowel projecting from the transfer box front face or use suitable wooden blocks to support the box to avoid damage to these items.

33. Drift out the differential rear bearing track.

NOTE: If it is required to completely strip down the transfer box to the basic casting, remove the level, filler and drain plugs.

IMPORTANT: Clean all parts ensuring any traces of Loctite are removed from faces and threads.

Ensure that the magnetic drain plug is thoroughly cleaned. Renew oil seals and examine all other parts for wear or damage, renew as necessary. f-,

--.

LT230R TRANSFER GEARBOX

1371

Reassembling

34. Ensure that all faces of t h e transfer box are clean.

35. Check that level/filler and drain plugs are in position.

36. Fit the two studs which are used for part retention of the extension housing.

37. Screw in the ‘radial’ dowel. It is important that its projecting blade is set radially in line with the tapped fixing hole centres in the transfer box casing.

Rear output shaft housing - to 73)

Dismantling

38. Using flange wrench 1861205 remove the flange nut. steel and felt washers.

NOTE: Ensure flange bolts are fully engaged in the wrench. h

39. Remove the output shaft flange with circlip attached. If necessary, use a two-legged puller.

NOTE: The circlip need only be released if the flange bolts are to be renewed.

40. Remove the speedometer spindle housing. This can be prised out with a screw driver.

41. Remove assembly from vice and support the housing to allow removal of the shaft, drifting it out by striking the flange end of the shaft.

42. CarefL!!!y prise nff the oi! catch ring llsing

2 screw driver in the slot provided.

43. Prise out and discard the seal(s) using tool

18G 1271.

44. Using circlip pliers 18G257 remove the circlip retaining the bearing.

45. Drift out the bearing from the back of t h e housing.

46. Remove the speedometer driven gear and spindle from the spindle housing.

47. Remove the ‘0’

48. Slide off the spacer and speedometer drive gear from the output shaft.

49. Clean all parts, renew oil seals and Nyloc flange nut and examine all other parts for wear or damage, renew as necessary.

Reassembling

50. Press the output bearing into t h e housing. D o not use excessive force. If necessary warm the housing and case.

51. Fit the bearing retaining circlip using circlip pliers

186257.

52. Fit a new dual lip oil seal (open side inward), with the seal in contact with the bearing circlip it is essential to use replacer tool 1861422.

NOTE: On early production two separate seals were used, these should be replaced with the new dual lip seal.

ST903 M n

(37 I

LT230R TRANSFER GEARBOX

53. Carefully charge the lips of the seal with grease.

54. Fit oil catch ring o n t o housing.

55. Fit oil seal into speedometer spindle housing

(open side inwards) with a suitable tubc.

56. Fit ‘0’ ring to speedometer spindle housing.

57. Lubricate seal and ‘0’ oil.

58. Locate speedometcr driven gear and spindle in spindle housing and push into position.

59. Slide speedometcr drive gear and spacer onto output shaft.

60. Fit output shaft to the bearing in the rear output shaft housing.

61. Examine the flange seal track to check for any damage that may harm the seal. Retain for fitting later.

62. Locate speedometer spindle housing assembly in the output shaft housing and push in flush with housing face.

-NOTE: Before fitting the rear output shaft housing to the transfer box casing the centre differential rear bearing track must be fitted.

63. Drift the centre differential rear bcaring track into the transfer box casing 1,5 mm (:,; in) below the outer face of the casing. Check the depth before proceeding.

Fitting rear output shaft housing to transfer box

64. Grease and fit housing gasket and locate the housing in position on the transfer box.

NOTE: If the differential rear main bearing track has been correctly fitted there will be a gap between the housing face and the gasket at this stage.

65. Apply Loctite 290 to the threads of the six housing securing screws, noting that the upper screw is longer. Fit the screws (with spring washcrs) evenly tightening them to the specified torquc.

This will press in thc rear main bearing track to the correct position and seat thc housi3g.

Centre differential Unit -

(Instructions 66 to 119)

Dismantling

66. Detach the high/low selector shaft and fork.

ST1189M

I1 I I II I

67. Using soft jaws secure the differential unit in a vice with t h e ‘stake’ nut uppermost.

68. Remove the peened-ovcr metal to facilitatc removal of t h e nut.

69. Remove the ‘stake’ nut using tool 18G1423.

70. Remove the differential unit from the vice.

71. Secure hand press MS47 in vice with collars

18G47BB/1 and using button 18G47BB/3 remove rear taper (twenty-four) roller bearing and collars

LST 47-1 for latest (twenty-three) roller bearing.

72. Substituting collars 18G47BW2 remove front taper roller bearing.

73. Remove the hand press from the vice.

STl166M ii i

74. Remove the high range (smallest) differential gear and its bush.

75. Mark the relationship of the highhow selector sleeve to the hub and remove the sleeve. f=:.

LT230R TRANSFER GEARBOX

137

*.I..

‘h

:c.

76. Using a suitable press behind the low range

(largest) gear carefully remove both high/low hub and low range gear together. Alternatively, the rear carrier bearing, high output gear and bush, high/low hub and sleeve and low output gear can

1 be pressed off in one operation by supporting the differential side of the low gear.

77. Using soft jaws secure the differential unit in the vice by gripping the inner hub splines.

78. Remove the eight retaining bolts and lift off the front differential case.

79. Lift off the front (upper) bevel gear and thrust washer.

80. Remove both pairs of side gears with their respective shafts and dished washers together.

81. Lift out the remaining rear (lower) bevel gear and thrust washer.

82. Remove the rear differential case from the vice.

83. Clean all parts, examine for wear or damage, renew as necessary. w

Obtaining differential backlash by checking bevel gear end-float

84.

Using soft jaws secure the rear differential case in the vice by gripping the inner hub splines.

85. Ensure that all differential components are dry to assist in checking end-float.

86. Using a micrometer measure one of the bevel gear thrust washers and note thickness.

87. Fit the thrust washer and bevel gear to the rear

(lower) differential case.

88. Assemble the side gears and dished washers on their respective shafts and fit to the rear case.

89. Measure the remaining bevel gear thrust washer, noting its thickness.

90. Fit the thrust washer and bevel gear to the front case.

91. Fit and align the front differential case tightening the eight securing bolts to the specified torque.

92. Ensure that the front bevel gear is fully in mesh by tapping i t down, using a punch through the front differential case.

ST1171M

99 - fG=?a

ST1169M

93. Measure the front bevel gear end-float with feeler gauges through the slots provided in the front differential case. This must be between 0,25 and

0,75 mm (0.001 and 0.003 in) maximum.

94. Invert differential unit in vice and repeat the above procedure (items 92 and 93) for the rear bevel gear in the rear differential case.

95. Return the differential unit to its former position in the vice i.e. with t h e front differentid case uppermost.

13'71

LT230R TRANSFER GEARBOX

ST1170M

96. Remove the eight securing bolts and lift off the front differential case.

97.. Remove the bevel gears and thrust washers, and side gear asscmblies.

98. Select correct thrust washers required for final reassem bly.

Reassembling

99. Fit the selected thrust washer and bevel gear to the rear (lower) differential case.

100. Assemble the side gears and dished washers o n their respective shafts and fit to the rear case.

101. Fit the other selected thrust washer and bevel gear to the rear case.

102. Lubricate all parts with oil.

103. Fit and align the front differential casc, locate the eight securing bolts and tighten to the specified torque.

104. Finally check that the differential gears revolve freely.

105. Place the front (outer) differential bearing on the front differential case and press into position using larger end of tool 18G1424.

106. Invert the differential unit in the vice.

107. Fit t h e low range gear (largest) to the rcar differential case (with its 'dog' teeth uppermost).

108. Press the high/low hub onto the splined area of the case. Check end-float of low range gear. See

Data at end of section.

109. Slide the highhow selector sleeve onto thc hub outer splines, observing the alignment marks.

110. Fit the bush into the high range (smallest) gear and slide t h e bushed gear onto the rear differential case. Check end-float of high range gear and running clearance of gear on bush. Scc data at end of section.

NOTE: If the clearances vary considerably from those specified in the data the assembly must be rebuilt.

111. Place the rear differential bearing on the rear diffcrcntial case and press i n t o position using t h e smaller end of tool 1861424.

ST1190M

112. Fit the 'stake' n u t using tool 1861423 and tighten to the specified torque.

113. Peen the nut flange into the slot provided.

114. Remove the differential unit from the vice.

115. Lubricate gears, bearings, sleeve and bush with oil.

116. Clean and check the high/low selector fork assembly for wear and rencw if necessary.

117. To renew the selector fork remove the square set screw retaining i t to the selector shaft and ensure any traces of Loctite are removed from the threads.

118. Refit the selector fork with the fork boss towards the three detent grooves. Align thc hole in the fork boss with the indent in t h e shaft nearest to the detent grooves.

119. Apply Loctite 290 to the set screw threads and fit the set screw to the correct torque.

120. Prop up the transfer box so that its front side is

'42: uppermost.

121. Fit the selector fork to the high/low selector sleeve in the differential assembly. g..

...

,..,

122. Locate the differential assembly and highllow

. ' ' - selector fork assembly into the transfer casc. It may be necessary to rotate the output shaft to ease fitment.

123. Fit the selector shaft detent ball and spring, apply

Loctite 290 to t h e detent plug threads, screw in the detent plug until the spring is just coil bound, then back off two complete turns.

LT230R TRANSFER GEARBOX

,,?:I:.

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Front output shaft housing

(Instructions 125 to 175)

Dismantling

124. Secure the housing in the vice, using soft jaws.

125. Remove the seven screws securing the differential lock selector side covcr and release thc side cover and gasket.

126. Remove the three screws securing the differential lock finger housing and l i f t O u t the complete assembly. e

126

128. Remove the detent plug from the top of the housing and lift out the spring and ball using a magnet.

129. Compress the selector fork spring inside the housing and slide out the spring locating 'C' caps.

130. Slide the sclcctor shaft out of the rear of the housing.

131. Remove the selector fork and spring through the side cover aperture.

132. Lift o u t dog sleeve from the back of the output shaft housing.

133. Using the flange wrench 18G1205 remove [he flange nut, steel and felt washers. A two-legged puller may be necessary.

NOTE: Ensure that flange bolts are fully engaged in the wrench.

134. Remove the output shaft flange with oil seal shield.

NOTE: These parts need not be separated unless the flange bolts are to be renewed.

ST1 I 7 3 M

127. Slacken the lock nut retaining the differential lock switch and unscrew the switch.

127, 1 d--

135. Drift t h e front output shaft rearwards o u t of the housing.

136. Slide off the collar from the output shaft.

137. Prise out and discard t h c oil seal(s), using service

137 I

LT230R TRANSFER GEARBOX

138. Using circlip pliers 186257 remove the circlip.

139. Remove the housing from the vice and drift out the bearing from inside.

140. Press out the differential front bearing cup and remove the shim behind it.

141. Clean all parts ensuring that any traces of Loctitc are removed from faces and threads.

142. Renew oil seals and examine all parts for wear or damage, renew as necessary.

Reassembling

143. Press the front bearing into the housing. Do not use excessive force, if necessary, warm the housing assembly and case.

144. Fit the bearing retaining circlip, using circlip pliers

186257.

145. Fit a new dual lip oil seal (open side inward) until the seal is in contact with the bearing circlip. It is essential to use replacer tool 1861422.

NOTE: On early production two separate seals were used, these should be replaced with the new dual lip seal.

155. Engage high or low

156. Check the rolling resistance of the differential, using a spring balance and a piece of string wound around the exposed splines on the high/low hub.

Little or no resistance will register.

157. Tighten the bolts a little at a time, occasionally checking the rolling resistance. With the correct shim selected and the bolts tightened to thc specified torque a pull of 1,s to 4,5 Kg (4 to 10 Ib) is required on the spring balance. This applies to new or used bearings.

158. If the reading is outside the abovc limits remove the front output shaft housing assembly from the transfer case.

159. Using a suitable extractor, withdraw the front differential bearing cup from the housing and exchange the shim for one of suitable thickness.

160. Rcfit the bearing cup.

161. Having obtained the corrcct rolling resistance prop-up the transfer box on the bench with thc front sidc uppermost.

162. Grease and fit the front output shatt housing gasket and locate the housing on the transfer box.

163. Apply Loctite 290 to the threads of the housing securing bolts and fit the eight securing bolts (with spring washers). Note that the upper middle bolt is longer.

164. T u r n the transfer box i n t o its normal operating position.

165. Fit both input and output flanges as follows.

166. Using flange wrench 18G1205 and a torque wrench pull up output shaft to corrcct position.

Check that the oil seal shield does not foul the housing .

NOTE: Ensure that flange bolts are fully engaged in the wrench.

- -

STSOSM

146. Carefully charge the lips of the seal with grease.

147. Slide the collar onto the front of the output shaft with its chamfered edge to the front.

148. Fit the output shaft through the back of the housing.

149. Examine the flange seal track to check for any damage that may harm the seal.

Obtaining bearing pre-load

150. Measure the original differential front bearing track shim, noting its thickness.

151. Refit the original shim.

152. Drift the differential front bearing track into the housing.

153. Grease and fit a new gasket and locate t h e front output shaft housing on the transfer box.

154. Loosely retain the h. , s i n g with the eight securing bolts (with spring w , ~ is longer. Do not i:illy tighten the bolts at this stage.

167. Slide the dog sleeve onto the rear of the output shaft ensuring that the selector groove in thc dog sleeve is to the front.

168. Compress the differential lock selector shaft spring, and fit it between the sclcctor fork lugs.

169. Locate the selector fork inside the side cover aperture in the housing engaging the groove in the dog sleeve on the output shaft.

170. Fit the differential lock selector shaft into the housing from t h e back, grooved (detents) end last, and pass it through the selector fork lugs and spring and into the front of the housing.

171. Rotate the selector shaft until the two flats are uppermost.

172. Compress the spring slightly between the fork lugs and fit the two locating ‘C’ caps.

17.5

LT230R TRANSFER GEARBOX

1371

STll79M

173. Fit the selector shaft detent ball and spring via t h e tapped hole in the top of t h e housing.

174. Apply Loctite 290 to the detent plug threads, screw in the detent plug until the spring is just coil bound, then back off two complete turns.

175. Loosely fit the differential lock switch in the tapped hole on top of the housing, leaving t h e locknut loose for adjustment.

176. Grease and fit the differential lock selector side cover gasket and fit the side cover, securing it with the seven bolts (with spring washers).

Differential lock finger housing -

(Instructions 177 to 183)

Dismantling

177. Remove and discard thc Nyloc n u t and release the lock lever and selector ‘finger’ from the ‘finger’ housing.

178. Remove and discard the ‘0’ rings from the selector finger and the selector finger housing.

179. Clean remaining parts, examine for wear or damage, renew as necessary.

Reassem bly

180. Fit new ‘0’ rings to the finger housing and selector finger and lubricate with oil.

181. Locate the selector finger in thc finger housing.

182. Fit the differential lock lever over the flats on the selector finger so that it will face forward in the operating position.

183. Fit the plain washer and a ncw Nyloc nut.

184. Fit t h e differential lock ‘finger’ housing assembly into the round aperture in the front output shaft housing locating the selector ‘finger’ on the flat on t h e selector shaft inside the housing.

185. Apply Loctite 290 to the ‘finger’ housing screw threads and fit the three securing screws (with spring washers) to t h e correct torque.

186. Grease and fit the differential lock selector side cover gasket and fit the side cover, securing it with t h e seven bolts (with spring washers).

187. Using a screwdriver inside the housing move the high/low selector shaft rearwards (i.e. into high range position) to provide access for fitting the yoke over the end of t h e selector shaft.

188. Locate the yoke on the selector shaft, apply iociiie 290 to the yoke set screw and fit iitc screw to the specified torque.

208

LT230R TRANSFER GEARBOX

192,199 194,198 191.197

210. Fit the oil seal into the front of the transfer box

(seal lip to rear of case) using replacer tool

18G 1422.

211. Prop up the transfer box on the bench with rear side uppermost.

212. Drift in the input gear front bcaring track from inside the back of the transfer box, using a suitable punch.

Highllow selector housing -

(Instructions 189 to 205)

Dismantling

189. Remove the selector fork grub screw completely.

190. Rcmove the cross shaft retaining circlip.

191. Withdraw the cross shaft from the selector housing with the operating arm attached.

192. Lift out thc sclcctor fork from the housing.

193. Remove the two ‘0’

194. Remove the operating arm from the cross shaft by rcmoving the retaining set scrcw.

195. Clean parts ensuring that all traces of Loctite are removed, examine for wear or damage, renew as necessary.

Reassembling

106. Fit the ‘0’ cross shaft.

197. Locate operating arm o n the shaft blind hole.

198. Apply Loctite 290 to the operating arm set scrcw threads and fit the set screw.

199. Locate t h e selector fork inside the housing.

200. Slidc the cross shaft into the housing passing it through the selector fork.

201. Fit thc ‘0’ ring to the fork end of t h e cross shaft

(inside the housing) and lubricate both ‘0’

202. Position the cross shaft fully home.

203. Locate the selector fork on the shaft blind hole.

204. Apply Loctite 290 to the fork grub screw threads and fit the grub screw.

205. Fit the circlip on the end of the cross shaft.

206. Grease and fit the gasket to the highhow selector housing aperture on t h e front output shaft housing.

207. Position the highhow selector housing so that the projecting selector fork engages the yoke side pins inside the housing.

208. Fit the six selector housing retaining bolts (with spring washers).

209. Prop up the transfer box on the bench with front side uppermost.

Input gear -

(Instructions 231 to 237)

Dismantling

213. Clean all parts, examine for wear and damage, renew as necessary. Remove the bearings only if they are to be renewed.

214. Secure hand press MS47 in vice and using collars and buttons 18647-7 remove the front taper roller bearing from the input gear assembly.

215. Reverse input gear assembly in hand press and rcmove the rear taper roller bearing.

216. Remove the hand press from the vice.

ST1184M

II I

Reassem bly

217. Locate thc front taper roller bearing on t h e input gear assembly and press the bearing fully home.

LT230R TRANSFER GEARBOX

(371

... .

, pzq

218. Repeat above procedure and fit the rear taper roller bearing.

219. Lubricate both bearings with oil.

220. Fit input gear assembly into the transfer box from t h e rear (gear end first).

Obtaining bearing pre-load cluster removed

221. Secure the mainshaft bearing housing in the vice.

222. Press out the rear input gear bearing cup and remove the shim behind it.

223. Clean the main bearing housing and measure original shim, noting its thickness.

224. Fit the original shim to the main bearing housing.

225. Locate the rear bearing cup on the main bearing housing and press it fully home.

226. Apply grease to the gasket and fit onto the t ransfcr box casing .

2-27. Fit the main bearing housing and tighten the two securing screws to the specified torque.

. I

i .

.,...

...

229. If the reading obtained is outside the above limits the original shim must be changed accordingly.

230. Remove t h e two screws retaining the mainshaft bearing housing.

231. Press out the rear bearing cup from the bearing housing and remove and discard the original shim.

232. Select a shim to the required thickness to obtain t h e correct pre-load of 0,02 to 0,07 mm (0.001 to

0.003 in) on reassembly.

233. Fit the shim to the main bearing housing and then press the rear bearing cup into position.

234. Fit the main bearing housing and tighten the two securing screws to the specified torque.

235. Grease and fit P.T.O. cover gasket and finally fit the P.T.O. cover securing it with six bolts (with plain washers) to the specified torque.

Intermediate gear assembly -

236. First I-emovc the needle roller bearings and spacer from the gcar assembly.

237. Clean the parts, including the thrust washers and lock plate and examine for wear or damage, renew as necessary. Refer to D A T A at end of section for thrust washer thickness.

238. Fit the '0' t h e intermediate shaft.

239. Fit the '0' ring into the front of t h e transfer case.

240. Lubricate thrust washers, bearings, shaft and spacer.

241. Fit needle bearings with spacer interposed.

If the bearings have plastic cages, the flangcd cnd of each cage must face the thrust washers, when fitted.

242. Fit front thrust washer to slot in transfer (plain side to case).

243. Locate gear assembly partially into the transfer case so that it rests on the front thrust washer.

244. Locate rear thrust washer (plain side uppermost) into slot in transfer case.

245. Gently push gear assembly into mesh.

246. Using a screwdriver through the intermediate shaft hole guide the locating tab on the rear thrust washer into the slot provided in the transfer case.

247. Align gear and thrust assembly and slide the intermediate shaft into the transfer box from the rear.

248. Align the shaft so that the lock plate slot in the end is on top.

. ?.

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228. Wind sllfficienr striflg around the gear !W!h (0 rotate the input gear. A pull of 1,4 to 3,6 Kg ( 3 to

8 Ib) is required on the spring balance. This applies to new or used bearings.

NOTE: The pre-load can only be measured while the Transfer gearbox is separated from the main gear box.

LT230R TRANSFER GEARBOX

249. Apply Loctite 290 to the lock plate bolt threads.

Locate lock plate into position and fit securing bolt (with spring washer).

Differential lock switch adjustment

257. Select differential locked position by moving the differential lock lever towards the right side of the transfer box.

258. Obtain a battery and connect a test lamp circuit to the differential lock switch.

259. Slacken the lock nut off and screw in the lock switch until the bulb is illuminated.

260. Turn the lock switch another half turn and tighten the lock nut against t h e housing.

261. Disconnect t h e battery and move the differential lock lever towards the left side of the transfer box to disengage the differential lock.

250.- Using a screwdriver via the bottom of the transfer case lift up the gear assembly and measure the end-float with feeler gauges. This should be between 0,08 and 0,35 mm (0.003 and 0.014 in).

257,261

259 258-

\ I

251. Grease and fit the bottom c w e r gasket.

252. Apply Loctite 290 to the ten bottom cover fixing bolts only.

253. Clean and fit the bottom cover, using the t e n bolts

(with spring washers).

Transmission brake assembly

254. Clean brake backplate and oil drip plate and apply silicone rubber sealant. Locate the backpiate on the rear output shairispeedometer housing so that the brake operating lever is on the right-side rear.

255. Fit the four Brako Durlok bolts, the lower two with plain washers, also retain t h e oil drip plate.

Tighten to specified torque.

256. Clean and fit brake drum and fit the two countersunk retaining screws.

Highhow gear change housing -

(Instructions 262 to 298)

Dismantling

262. Remove the split pin from the clevis pin at the top of the differential lock cross shaft lever which secures it to the gear change cross shaft.

263. Remove the washer and clevis pin and the anti- rattle nylon strip.

264. Mark the position of the high/low gcar change operating arm on the splined shaft o f the gcar change crank arm.

265. Slacken the clamp bolt and remove the operating arm.

266. Remove the four bolts from the top of the gear change housing and iift off the grommet piate grommet, gate plate and gasket.

267. Remove the split pin from t h e gear change crank arm clevis pin and remove the clevis pin.

268. Remove the circlip from t h e highilow gear change lever bush.

269. Withdraw the gear change lever from the housing, with ball and socket bush.

LT230R TRANSFER GEARBOX

. . c. ...

I,:

270. Rcmove the two countersunk screws from t h e housing end cover.

271. Remove the housing end cover.

272. Remove the two ‘0’

273. Remove the cross shaft from the housing.

274. Compress t h e detent spring and remove t h e gcar change arm from inside the housing.

Reassem biy

279. Fit the two

280. Fit the two ‘0’

281. Lubricate

282. Clip the detent spring onto the detent plate.

283. Fit detent plate assembly into housing and retain from outside with two Nyloc nuts (with plain washers).

284. Compress thc detent spring and f i t the gear change crank arm in t h e housing.

285. Fit cross shaft into position locating end in the crank arm.

286. Fit the housing end cover to support the other end of the cross shaft.

287. Finally secure the housing end cover with the two countersunk screws.

288. Before refitting the gear change lever remove the clevis pin bushes and the Nylon socket bush and ball.

289. Clean all parts, examine for wear o r damage, renew as necessary.

290. Fit and grease gear lever ball and Nylon socket bush to gear lever.

291. Fit and grease clcvis pin bushes.

292. Locatc gear change lever assembly in cross shaft

(do not fit socket bush retaining circlip at this stage).

293. Align gear change lever end with crank arm fork ensuring that the gear lever is crankcd rcarwards and fit clcvis and split pin.

294. Finally secure Nylon socket bush with circlip.

295. Grease and fit gasket to gear change housing face.

296. Fit the gate plate.

297. Fit the grommet.

298. Fit the grommet plate and retain with the four securing bolts (with spring washers).

275. Remove t h e two

276. Remove and discard the two Nyloc nuts retaining the detent plate.

277. Remove the detent plate and spring from the housing.

278. Clean all parts, examine for wear or damage, renew as necessary.

137

LT230R TRANSFER GEARBOX

299. Before refitting the high/low connecting rod and gear change operating arms remove the respective clevis pins and Nylon bushes. Clean and examine for wear or damage, renew as necessary.

300. Grease and fit the Nylon bushes to the high/low selector and gear change opcrating arms.

301. Assemble both operating arms to the connecting rod with clcvis pin, plain washer and split pin.

302. Slacken the gear change operating arm clamp bolt and fit the operating arm on to the splined shaft projecting from the high/low gear change housing, carefully aligning it to the marks on both camponents.

303. Tighten the clamp bolt to the specified torque.

304. Before refitting the differential lock cross shaft lever and pivot bracket remove the respective clevis pins and Nylon bushes. Also remove the split pin retaining the cranked lever and disconnect it. Clean and examine for wear or damage, renew as necessary.

305.- Fit the cranked lever to the bottom of thc cross shaft lever and secure with a new split pin (with plain washer).

NOTE: Early gearboxes were fitted with a short connecting link secured by a ‘Nyloc’ nut.

306. Grease and fit t h e Nylon bushes to the middle pivot of the cross shaft lever.

307. Fit the cross shaft lever to the (loose) pivot bracket with the clevis pin, washer and split pin.

308. Fit the cross shaft lever fork (top) to t h c gear change cross shaft.

309. Locate the anti-rattle Nylon strip and fit t h e clevis pin, plain washer and split pin.

310. Fit the cranked lever, at thc bottom of the differential lock cross shaft lever, to the lock lever and retain the clevis pin and plain washer with a new split pin.

311. Grease and fit the Nylon bushes to the operating arm on the selector housing cross shaft.

Adjustment of highllow connecting rod

312. This operation is carried out in situ or on the

313. bench, after assembly to the main gearbox.

Remove the four bolts from the top of the gear changc housing and lift off the gear changc lever grommet plate and the gcar change lever

314. grommet. Replace the four bolts tcmporarily to retain the gate plate in position.

Check that t h e gear lever does not foul t h e gate plate when high or low range is selected. If

315.

316. adjustment is required carry out the following procedure.

*Slacken off the connecting rod locknuts.

Move gear change lever into high range

(rearwards) and move the operating arm on the selector housing cross shaft into high range

(forwards).

317.

318.

Tighten locknut(s).

Check that the gear change lever does not foul the

319.

36 gate plate in this position.

Engage and check low range in the same way.

320. After adjustment return the gear change lever to the high range position.

321. Remove the four bolts retaining the gate plate and refit the grommet and grommet plate.

322. Refit the four bolts (with spring washers).

* On early versions of the transfer gearbox a different connecting rod fork end was used with a single locknut. In this case the following method of adjustment is recommended.

(a) Disconnect t h e top of the differential lock cross shaft lever from the gear change cross shaft.

(b) Remove the four bolts retaining the gear change housing to the remote gear change housing on the main gearbox.

(c) Lift up the housing assembly (with the connecting rod attached) and rotate it as required to vary the length of the connecting rod.

Transfer box mounting -

323. Fit the rubber mounting plate to the right sidc of the front output housing by fitting the four securing bolts (with new lock tabs).

Handbrake linkage

324. Locate the handbrake linkage bracket in position on the right hand side of the transfer box casing and secure as follows.

325. Fit the two bolts (with spring washers) and distance pieces to retain the front sidc of the linkage bracket.

326. Fit the two bolts (with spring washers) to secure the rear end of the linkage bracket. The lower bolt is shorter.

327. Insert the clevis pin through the brake operating lever, fit the handbrake link, plain washer and split pin.

LT230R TRANSFER GEARBOX

(371

.......

..-!:

DATA

Input shaft bearing pre-load ..................................

Intermediate gear end-float ..................................

Intermediate gear thrust washer thickness ................

Centre differential rolling resistance - intermediate gear cluster and output shaft flange) ......

Input gear rolling resistancc - intermediate gear cluster) .....................................

Differential pinions backlash .................................

Output shaft bearing pre-load ...............................

Low range gear end-float

High range gear end-float .....................................

0,02 to 0,07 mm (0.001 to 0.003 inch)

0,08 to 0,35 mm (0.003 to 0.014 inch)

2,?0 to 2,75 mm (1.06 to 1 .@8

1,8 to 4,5 Kg (4 10 Ib) pull

1,4 to 3,6 Kg (3 to 8 Ib) pull

0,02 to 0,07 mm (0.001 t o 0.003 inch)

0,02 to 0,0? mm (0.001 to 0.003 inch)

0,05 to 0,15 mm (0.002 to 0.006 inch)

High range gear/bush running clearance diameter ...... 0,03 to 0,09 mm (0.0012 to 0.0035 inch)

<" ,

371

LT 95 FOUR SPEED GEARBOX

REMOVE LT 95 FOUR SPEED GEARBOX WITH

INTEGRAL TRANSFER BOX

MODELS

Service tools:

RO 1001

- mechanical chassis spreader is also required.

The gearbox should be removed from underneath t h e vehicle using a suitable lifting hoist. Number 3 , chassis cross-member is removable to allow easy removal of the gearbox.

WAKNING: It is essential, because of the considerable weight and offset position of the centre of gravity of the gearbox, that a hydraulic transmission hoist of adequate strength and stability is used. Failure to observe this precaution could result in the hoist tipping over and causing serious personal injury or damage to the gearbox.

Suitable hydraulic lifting equipment ( A ) is made by

Blackhawk International Limited. A special adaptor plate (B) is produced by Claydrum Engineering

Services for holding the Land Rovcr V8 gearbox. This adaptor plate can be used with various transmission hoists provided they meet the safety requirements indicated above.

When removing the chassis cross-member, do not allow it to fall. Aftcr removing the fixings, use a spreader on the chassis side members to free the cross-member.

Remove the cover plate from the front lower half of the bell housing.

Remove the clutch slave cylinder from the bell housing.

Position the transmission hoist under the gcarbox and support it.

Release the t w o rear gearbox mounting brackets from the chassis side mcmbers.

Support the engine under the sump.

Pass the safety chain around the gearbox and make fast.

Remove the bell housing bolts (eight bolts).

Withdraw the gearbox from thc engine.

Fit the lifting bracket R O 1001 to facilitate any subsequent removal from the transmission lift.

I t. d s

-a

After refitting the gearbox i n t o the vehicle, refill the main and transfer gearboxes with the correct grade oil, to the oil level plug hole.

For further information regarding the hydraulic transmission hoist and the special gearbox adaptor plate, please contact the equipment manufacturers direct. Their addresses are as follows:-

Transmission Hoist

67556 (T-3)

Blackhawk Automotive Limited

Brookfield Industrial Estate

Leacon Road

Ashford

Kent, England

Tclcphonc: Ashford (0233) 32151

Telex: 965621 BLUK G

Gearbox Adaptor Plate

DS RT

Claydrum Engineering Services

P . 0 . Box 5

Clayland Avenuc

Worksop, England

Tclcphone Worksop (0909) 4802 1 Remove

Gear change levers.

Central section of exhaust system.

Disconnect

Handbrake and speedometer cables.

Front and rear propeller shafts from the gearbox.

Vacuum pipes and electrical leads from differential lock actuator.

Electrical leads from reverse light switch.

Make any remaining disconnections and note t h e following important points during removal.

LT 95 FOUR SPEED GEARBOX

1371

OVERHAUL LT

95

FOUR SPEED GEARBOX

The following overhaul instructions assume that the gearbox is removed from the vehicle and the oil drained.

Remove the clutch slave cylinder, release mechanism and bearing assembly, stand the gearbox on a wood block on the bell housing end.

REMOVE AND OVERHAUL SPEEDOMETER

DRIVE HOUSING

1. Remove the brake drum retaining screws and withdraw the drum.

2. Remove the four bolts retaining back plate, remove oil catcher and back plate assembly.

11. Drive out the rear output shaft, using a hide mallet on the threaded end.

12. Slide off the spacer and speedometer worm.

. ..

::,-.

- ,

..,

3. Remove the eight bolts and withdraw the speedometer drive housing.

4. Remove the speedometer spindle housing.

5 1 d . ift

Y... niit the

V I . L . . V driven

.A...".. o p a r b - - .

-..-

6 . Take off the '0' ring seal.

7. Remove the thrust washer.

8. Withdraw the oil seal.

9. Remove the locking n u t , using a flange tool, washer and felt seal, output coupling flange to output shaft.

10. Withdraw the coupling flange complete.

ST1025M

13. Withdraw the oil shield.

14. Prise-out the oil seal.

15. Remove the circlip.

16. Tap out the ball bearing race.

LT 95 FOUR SPEED GEARBOX

ST1204M

I #

Check differential pre-load

This check must be carried out if a replacement speedometer drive housing is to be fitted. The check is also required if a replacement gcarbox, differential unit or diffcrcntial unit bearing is being fitted.

17. Measure and record the thickness of the new joint washer for the speedometer drive housing.

18. Offer the spcedometer housing, less joint washer. to the gearbox.

19. Measure the clearance between the drive housing and gearbox j o i n t faces. This must be 0,lO to

0,15 mm (0.004 to 0.006 in) more than the recorded thickness of the new joint washer. With the gasket fitted and the bolts tightened to 3 kgf.m

(22 Ibf.ft) a final rolling'resistancc check should be made using a spring balance and string wrapped round the differential case. The resistance should be 14-16 Ibs (6-7 kg). The differential lock must be disengaged to allow free rotation of the u n i t whilst making this chcck.

20. T o adjust the joint face clearance, adjust the thickness of shimming fitted behind the rear bearing outer face as follows: instructions 21 and

22.

21.

22.

Drive out the bearing outer race.

Withdraw the shim washer and selcct a replacement of the required thickness. Shim thickness range is 1,65 to 2,80 mm (0.065 to

0.110 in) in 0,05 m m (0.002 i n ) stages.

Assemble the housing

23. Fit the rear output shaft ball bearing and circlip.

24. Press in the output coupling flange oil seal, open face first, until the seal plain face just clears the chamfer on the seal housing bore.

25. Fit the oil shicld, which must be a close fit on the speedomcter housing.

26. Fit t h e speedometer worm I'ollowed by the spacer.

27. Fit the rear output shaft.

28. Fit t h e coupling flange.

29. Fit the felt seal, plain washer and locking nut to secure the output flange and tighten to the correct torque.

30. Assemble the following parts to the speedometer spindle housing:

31. Fit the oil seal.

32. Fit t h e thrust washer.

33. Fit a new '0' seal.

34. Fit the speedometer driven gear and spindle.

35. Fit the speedometer spindle housing assembly to the drivc housing.

#%i

. '.I

Assemble speedometer drive housing to gcarbox

36. Place a new joint washer in position.

37. Offer the drive housing to the gearbox and engage the rear output shaft splines in the differential unit.

38. Position the flat on the drivc housing adjacent to the flat on the intermediate shaft.

39. Secure the assembly with eight bolts and evenly tighten to the correct torque.

40. Fit back plate assembly.

$1. oil catcher and with 'dyiosii,

42. Tighten special bolts to 55 to 60 Ibf.ft (75 to 80") noting t h a t plain washers are fitted.

::‘:?2 y . , .:

REMOVE AND

TRANSFER GEAR

OVERHAUL MAINSHAFT

Special tool: lSC1388 -

1. Remove thc mainshaft rear bearing housing.

2. Lift out the roller bearing.

3. Remove the snap-ring.

4. Withdraw the shim washer.

5 . The transfer gcar is retained on the splines with

Loctite 275. Use a puller 1861388 to withdraw it.

NOTE: The roller bearing outer race is located by a roll pin which must be punched-out before the race can be removed.

LT 95 FOUR SPEED GEARBOX

1371

REMOVE AND OVERHAUL INTERMEDIATE

GEARS ASSEMBLY

Special tool:

R01003

1. Remove t h e speedometer drive housing.

2. Remove the gearbox bottom cover.

3. Screw a suitable extractor into the 8 mm threadcd hole provided in the intermediate gear shaft.

4. Hold the intermediate gear cluster in position and withdraw the shaft.

5. Insert the slave shaft R01003 to retain together the gears assembly.

6. Withdraw the intermediate gears assembly.

7. Slide the thrust washers, bearings and gears from the slave shaft.

8. The input gear and outer member is a riveted assembly and no dismantling is permitted.

Assembling

Fit the transfer gear to the mainshaft.

Fit the shim washer and snap-ring.

Check the end-float between the shim washer and snap-ring. End-float to be 0,050 mm (0.002 in) maximum. Shim washer range 1,s to 2,O m m

(0.071 to 0.079 in) in 0,05 mm (0.002 in) stages.

Fit the roller bearing and rear bearing housing.

9. Remove the ‘0’ gear shaft.

10. Wash and degreasc all parts and inspcct for wear and renew if necessary. When new, the thrust bearing washers have a lead/tin coating, i f this only has worn away there is no need to renew them.

Assemble intermediate gears

11. Place the slave shaft on t h e bench, extractor thread end uppermost.

12. Fit a pear-shaped thrust washer, inner ring and a thrust bearing washer to the shaft (ring grooved face downwards).

13. Fit a needle-roller bearing and the ‘high’ gear

(plain face first) to t h e shaft.

LT 95 FOUR SPEED GEARBOX

ST12 1 OM

14. Position a thrust bearing washer on the ‘high’ gear.

15. Fit a spacer, nccdlc-roller bearing and a further spacer to the input gear inner member.

16. Position the assembled input gear on the shaft and engage the lower spacer in the previously positioned thrust bearing washcr.

17. Locatc a thrust bearing washer over thc upper spacer.

ST121

20. When the foregoing bearing clearance check has been completcd. slidc the gcars and slave shaft assembly into the transfer gearbox and engagc thc selector forks.

21. Withdraw the slave shaft and lubricate the bearings through the shaft aperture.

22. Fit the intermediate shaft and ‘0’ with the flat on the shaft toward t h e differential u n i t .

23. Measure the clearance between the rear thrust washer and the gear casing. This must be 0,15 to

0,23 mm (0.006 to 0.009 in).

24. Adjustment is carried out by substituting one or both of thc thrust washcrs. The washers are available in 33.5 mm (0.139 in), 3,63 nini

(0.143 in) and 3,74 mm (0.147 in) thicknesses.

25. Refit the gearbox bottom cover.

26. Refit the speedometer drive housing.

18. Fit a needle roller bearing and the ‘low’ gear (plain side last) to the shaft.

19. Fit the remaining thrust needle bearing, inner ring and thrust washer (ring grooved face upwards).

ST1213M

...

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..:

REMOVE AND OVERHAUL DIFFERENTIAL UNIT

Special tool:

18G47BB - bearing extractor

1 . Select the differential lock.

2. Rcmove the differential lock actuator assembly

3. Remove the front output shaft and housing.

4. Remove the speedometer drive housing.

5 . Remove the intermediate cluster assembly.

6. Remove the differential assembly.

NOTE: During dismantling it is essential that all components are marked in their original position and relative to other components, so that if original components are refitted, their initial setting is maintained.

7. Press off the roller bearings using tool 18G47BB.

8. Withdraw the high-speed gear, which is secured by

Loct i tc.

LT 95 FOUR SPEED GEARBOX

11. Remove the casing securing bolts.

12. Lift off t h e rear case assembly (and oil retaining ring -

13. Withdraw the side gear (and thrust washer - boxes).

14. Slidc out the cross-shafts and rcmovc the bevel pinions and thrust washers from the front case assembly.

- boxes) to dismantlc the front case assembly.

ST1216M

NOTE: From gearbox numbers 1300 3481A and 1700

0007A the following modifications have been made to the differential.

A. Introduction of side gear bushes.

B. Improved thrust washers.

C. Addition of thrust washer on side gears.

D. Modified cross pins.

E. Addition of oil retaining ring.

The new differential part number FRC 7740 is only interchangeable with superceded unit part number 594

340.

ST1215M

I I

9. Remove the fixings, low-speed gear to casing.

10. Withdraw the gear.

ST1799M

LT 95 FOUR SPEED GEARBOX

NOTE: If replacements are required, replace the following items 16 and 17 as sets.

16. Bevel pinions and side gears (set of six).

17. Cross-shafts (set of two).

18. Check the gear teeth for damage.

19. Check all parts for satisfactory general condition including the sidc gear bushcs.

NOTE: The differential case halves are a matched pair, and halves must not be changed individually.

Assemble differential

CAUTION: It is essential that during the following assembly all components are well lubricated with new oil of the correct grade.

20. Fit a sidc gear into the rear casing.

21. -Fit a side gear into the front casing.

22. Fit the bevel pinions, thrust washers and cross- shafts into the front casing.

23. Fit thc rear casing to the front casing. Tighten the bolts evenly in sequence to thc correct torquc. Use

Loctite 275 on threads.

24. Offer the low gear to the differential casing.

25. Align the fixing holes and fit the bolts evcnly in sequence to the correct torque. Usc Loctite

26. Fit the roller bearings and refit the diffcrential unit.

Assemble differential to gearbox

27. Refit the differential unit.

28. Refit the speedometer drive housing.

29. Refit thc frofit output shaft and housing.

30. Rcfit the diffcrential lock actuator assembly

NOTE: If a replacement differential unit is being fitted, carry out the ‘Differential hearing pre-load check’, described in ‘Speedometer drive housing

Overhaul’.

REMOVE AND OVERHAUL TRANSFER GEAR

LEVER AND CROSS-SHAFT

1. Remove the top cover.

2. Slacken the selector finger pinch bolt.

3 . Drive out the retaining pin, gear lever to cross- shaft.

4. Withdraw the gear lever.

5 . Withdraw the cross-shaft and spacer.

6. Lift out the selector finger.

7. Remove the retaining plates.

8. Withdraw the scaling rings.

ST121

NOTE: If the differential case or bearings have been replaced, carry out the ‘Differential bearing pre- load check’.

Assemble gear lever and cross-shaft

9. Position the selector finger in t h e gearbox.

10. Fit the cross-shaft and spacing collar and engage-i the selector finger.

11. Fit the sealing ring and retaining plate at the R . H . side of the gearbox.

12. Fit the gear lever and retaining pin.

*- ,

13. Fit the remaining sealing ring and retaining plate.

14. Tighten the selector finger pinch bolt.

15. Select ‘High’ transfer range, that is, the larger intermediate gear engaged.

16. Slacken the selector finger bolt.

17. Rotate the cross-shaft until the gear lever is inclined 45 degrees to the vertical position.

LT 95 FOUR SPEED GEARBOX

137(

12. Withdraw the two detent balls.

13. Lift out the spacing rod and spring.

14. Remove the blanking plug.

15. Withdraw the detent spring from the cross drilling.

ACO

ST 1 1 -

18. Tighten t h e selector finger pinch bolt.

19. Fit the top cover using a new joint washer and evenly tighten the retaining bolts.

. .

.h.,.

REMOVE AND OVERHAUL TRANSFER BOX

SELECTORS AND SHAFT

1. Remove the speedometer drive housing.

2. Remove t h e transfer gearbox top cover.

3. Select ‘Low’ range transfer gear.

4. Drive out the retaining pin from the front selector fork sufficient to free t h e fork.

5 . Ease the differential u n i t to t h e rear.

6. Push the forward selector fork forward on t h e shaft.

7. Pull to the rear on the rear selector fork to move the selector shaft out of engagement with t h e detent balls in the casing rear face.

8. Remove the pinch bolt o n the rear fork.

9. Partially withdraw the selector shaft and lift out the selector forks.

10. Remove the retaining pin from the front fork.

11. Withdraw t h e selector shaft, closing the shaft housing by hand to prevent the detent balls from dropping into the casing.

Assemble shaft and selectors

16. Position the detent spring in t h e inncr bore in the cross drilling.

17. Locate the detent ball on the spring.

18. Enter t h e selector shaft, push the ball against the spring and push in the shaft.

19. Fit the detent ball, spring and spacing rod to the vertical drilling.

20. Position thc rear selector fork, plain face to rear, in the gearbox.

21. Position t h e front selector fork, extended boss to the rear, in the gearbox.

22. Align the retaining pin holes and engage the selector shaft in t h e selector forks.

23. Fit the retaining pin, front fork to shaft.

24. Set transfer gears in ‘Neutral’ position.

25. Adjust the rear fork position until there is 0,12 to

0,25 mm (0.005 to 0.010 in) clearance between the front face of the rear fork and the rear face of the input gear inner member.

26. Tighten the rear fork pinch bolt.

LT 95 FOUR SPEED GEARBOX

Overhaul assembly

5. Hold the output shaft in a vice or use a flange restraining tool and remove t h e flange retaining n u t and washer.

6.

Withdraw the coupling flange complete with mudshield.

7. If required, press off the mudshield.

8. Press out the shaft toward the rear.

9. Withdraw the oil seal.

10. Remove the circlip.

11. Withdraw the output shaft bearing.

12. Wash and degrease all parts, examine for wear and renew as necessary.

27. Fit the blanking plug to the cross drilling.

28.-Fit the transfer box top cover using a new joint washer and evenly tighten the bolts to the correct torque.

29. Fit the speedometer drive housing.

ST 1223M

RER E

ND OVER€

SHAFT AND HOUSING

IUL FRONT

OUTPUT

Remove output shaft assembly

1. Remove the differential lock actuator assembly.

2 . Remove the six retaining bolts, spring washers and gasket.

3 . Withdraw the output shaft and housing complete.

4. Lift o u t the lock-up dog clutch.

Assemble output shaft assembly to housing

13. Fit t h e output shaft bearing and secure with the ci rcl i p.

14. Fit the oil seal, lip side towards the bearing.

15. Press in the output shaft from t h e rear.

16. Fit t h e coupling flange complete with mudshield and flange bolts. Secure with the locking nut to the correct torque.

REMOVE AND OVERHAUL BELL HOUSING AND

CLUTCH RELEASE

I . Withdraw t h e locating staple from the clutch release slecve and release lever.

2. Lift out the release sleeve and bearing assembly.

3. Remove the bell housing fixings and make a note of the position of each bolt and nut.

4. Withdraw t h e bell housing complete with clutch release lever.

5. If required, remove the push rod clip and the spring clip and withdraw the clutch release lever.

LT 95 FOUR SPEED GEARBOX

REMOVE AND OVERHAUL GEAR CHANGE

SELECTORS

1. Remove the bell housing.

2. Select neutral, remove the reverse light switch and remove the gearbox top cover and joint washcr.

3. Lift o u t t h e dctent springs.

4. Withdraw the detcnt balls, using a small magnet or an air blast.

5 . Slacken the pinch bolt securing the reverse selector finger.

6. Drive out the four retaining pins until the shafts are free in the selectors.

ST1225M

. .

Assemble clutch release and bell housing

6. If removed, fit the release lever spring clip.

7. Apply a thin film of Unipart Universal or other suitable jointing compound around the three selector shaft holes in the bell housing rear face.

8. Fit the bell housing, locating on the dowels.

9. Apply a thin film of molybdcnum disulphide grease onto the f r o n t cover extension sleeve.

10. Fit thc rclcase sleeve and bearing assembly.

11. Fit the locating staple to the clutch reiease sleeve and lever.

7. Tap out the selector shafts.

8. Withdraw the selector jaws and forks.

9. Withdraw the two interlock plungers from the cross-drilling.

10. Rcmove t h e lock-wired pivot bolt.

11. Lift out the reverse cross-over lever.

Overhaul

Examine all parts and renew i f worn. Renew thc detent springs. Ensure that t h e retaining pins are an interference fit, if not, renew.

. .

ST 1

1371 LT 95 FOUR SPEED GEARBOX

Assemble gear change selectors

12. Withdraw the retaining pins from the selector jaws.

13. Engage the cross-over lever and locate fully in the groove in the reverse idler with the peg in the top of the cross-over lever fully in the selector finger.

14. Start the pivot bolt in the lever threads. Should it not start properly move the lever away from the selector finger but not out of engagement with the idler.

15. Locate the first/second gear selector fork in the groove in the outer member, with the boss on the fork to the rcar. Position the boss to the R.H. side of the box.

16. Locate the third/fourth gear selector fork in the groove in the outer member. Position the fork with the retaining pin entry hole at the top R.H. side.

17. Fit the third/fourth gear selector shaft and interlock pin assembly and secure to the selector

. fork with a retaining pin.

18. Fit the two interlock pins to engage in the grooves each side of the third/fourth gear selector shaft.

19. Position the reverse stop hinge plate and selector j a w in t h e gearbox, adjacent to t h e third/fourth gear selector jaw.

20. Fit the reverse gear selector shaft and engage the selector jaw and hinge spring.

21. Push the shaft home and engage the reverse cross- over lever selector finger. Do not secure the pinch bolt at this stage.

22. Secure t h e revcrse gear selector jaw to the shaft with a retaining pin.

26. Move the reverse shaft forward until the selector jaw abuts the casing.

27. Holding the reverse shaft as described in the previous item, move the reverse selector finger forward on the shaft until it abuts the casing, then move it rearward until it is just clear of the casing.

28. Place a 0,25 mm (0.010 in) feeler gauge between the upper edges of the reverse and third/fourth selector jaws.

NOTE: The edges of the selector jaws taper slightly, therefore, it is important that the feeler gauge is positioned between the upper edges.

29. Hold the reverse and third/fourth selector jaws together to retain the feeler gauge, then rotate the reverse selector finger until it abuts the third/fourth selector shaft and tighten the pinch bolt.

24 23

A+-

30. Wire lock the cross-over lever pivot bolt.

31. When fitting the hinge spring to the reverse stop hinge, first engage t h e large hook around the selector shaft, as illustrated, before fitting the small hook to the reverse stop hinge pin.

ST 1227M

23.

24.

Posi!i~n thp first,/secogd up?ir c p l p r t n r

J iaw in the gearbox.

Fit the first/second gear selector shaft; engage the selector jaw and selector fork as the shaft is pushed home.

25. Fit the retaining pins, fitting the rear pin first.

LT95 FOUR SPEED GEARBOX

(371

6. Lift out the reverse idler gear assembly.

7. Remove the circlip and plain washer.

8 Lift out the needle rollcr bearings and further plain washer.

9. Withdraw the remaining circlip.

32. Fit the detent balls and springs.

33. Selcct neutral and using a new joint washer, fit thc gearbox top cover and secure with the eight bolts, and evenly tighten to the correct torque.

34. Fit the reverse light switch

35. Fit the bell housing.

S T l 2 3 1

REMOVE AND OVERHAUL REVERSE IDLEK

GEAR AND SHAFT

Special tool:

18G1335

1. Remove the gearbox sidc cover.

2. Remove the gearbox bottom cover.

3. Remove the bolt securing the idler gear shaft in t h e gearbox casing.

4. Withdraw the idler gcar shaft, using cxti-actor

18G1335.

5 . Remove t h e ‘0’

Assemble reverse idler gear and shaft

10. If removed, fit the shaft support bush, using

Locquic primer grade ‘T and ‘AVV’ grade.

11. Fit the circlip to selector groove end of thc gcar.

12. Fit thc plain washer and two needlc rollcr bearings.

13. Fit the outcr plain washcr and secure with circlip.

14. Fit a new ‘0’

15. Offer the idler shaft to the gearbox and align the retaining bolt holes.

16. Smear clean gearbox oil onto the ‘0’

17. Position the reverse idler assembly in the casing.

18. Engagc thc sclcctor foot in the idler gcar groove.

19. Drive in the idler gear shaft until t h e retaining bolt holes are aligned.

20. Before fitting the retaining bolt, trcat the threads with Locquic primer grade ‘T’ and allow to dry.

Then, fit thc bolt using Loctite Studlock grade.

21. Fit the gearbox bottom cover using a new joint washer and secure with the fourteen bolts evenly tightening to the correct torque.

22. Using a new j o i n t washer fit the side cover with the four bolts and tighten to thc spccificd torque.

LT 95 FOUR SPEED GEARBOX

REMOVE AND OVERHAUL FRONT COVER AND

OIL PUMP

Service tools:

R01005 - tool

18G134 -

18G134DG - tool for fitting oil seal and oil feed ring.

1. Lift out the retainer staple from the clutch release bearing assembly and t h e release lever. See clutch release overhaul.

2. Withdraw the release bearing assembly.

3. Remove the slave cylinder pushrod.

4. Remove the spring clip.

5 . Withdraw the clutch release lever.

6. Remove the front cover assembly, complete with oil pump joint washer.

7. Remove the shim washer located between the front cover and thc layshaft front bearing.

STl234M

16. Press in the oil feed ring, using 18G134 guide and

18G134DG adaptor.

17. Fit the ball, spring and plug. When fitted, the plug must be flush with, or n o t more than 0,25 mm

(0.010 in) below the f r o n t cover rear face.

18. Fit the oil pump ring gear.

ST1235M

Overhaul

8. Remove the pump cover gasket and oil pump drive.

9. Withdraw the oil pump ring gear.

10. Remove the oil feed ring.

11.

12.

Withdraw the oil seal.

Remove the plug and withdraw the ball and spring from the relief valve housing.

13. If required, drift off t h e extension sleeve. Fit a repiacemenr using iocrite 275 grade.

Reassemble

14. Press in the oil seal, plain face first, using 186134 guide and 186134DG adaptor.

15. Align the centre hole of three in the oil feed ring with the oil delivery hole in the front cover.

ST1236M

LT 95 FOUR SPEED GEARBOX

(37(

Fit cover assembly to gearbox

19. Position the layshaft bearing shim washer.

20. Position t h e front cover assembly and loosely fit the fixings.

21. Fit the oil pump drive gear to engage the drive square in the layshaft.

22. Fit the oil pump cover and joint washer and fit the fixing screws and washers and carefully tighten to the correct torque.

23. Fit the gauge R01005 to align the primary pinion with the bell housing.

24. Visually check that the front cover is concentric about the primary pinion. Adjust the front cover position about its fixings to suit.

ST1238M

ST1237M

25. When satisfactory, tighten the front cover fixings.

26. Fit the clutch release lever and spring clip.

27. Fit the slave cylinder push-rod.

28. Fit the release bearing assembly.

29. Fit the retainer staple to the clutch release bearing assembly and lever.

Assemble bearing plate assembly

NOTE: To replace a bearing plate, a bearing plate and gearbox casing mated assembly must be fitted.

10. Locate t h e cone i n t o the third/fourth-speed synchromesh unit.

11. Lubricate the oil tube, using clean gearbox oil.

12. Position the joint washer.

13. Engage the layshaft with the primary pinion and front bearing outer member.

14. Fit the bearing plate and layshaft.

15. Align the bearing plate with the gearbox casing and slide home the dowel sleeves.

16. Refit the studs. Smcar Loctite 'Studlock' grade

CVX, on t h e two upper studs securing threads before fitting.

17. Fit the oil pump drive gear.

18. Using a new joint washer fit the oil pump gear cover.

19. Fit the bell housing.

REMOVE AND OVERHAUL BEARING PLATE

ASSE MB LY

1. Remove the bell housing and position the gearbox with the front end uppermost.

2. Remove the oil pump gears cover and joint washer.

3. Withdraw the oil pump drive gear.

4. Temporarily remove the four fixing studs from the gearbox front face.

5 . Ease the bearing piate away from the gearbox.

6. Withdraw the two dowel sleeves which locate the bearing plate.

7. Withdraw the bearing plate assembly complete with primary pinion and layshaft.

8. Withdraw the joint washer.

9. Withdraw the layshaft.

LT 95 FOUR SPEED GEARBOX

REMOVE AND OVERHAUL PRIMARY PINION

1. Remove the bell housing.

2. Remove the front cover and oil pump assembly.

3. Remove the bearing plate assembly.

4. Remove the circlip.

5 . Lift off the shim washer.

6. Press out the primary pinion.

~ ~~~ ~ ~~ ~

Assemble primary pinion

9. Check that the orifice drilkd in the oil tube is clear.

10. During refitting, take care to avoid damage to the oil tube. Rotate the shaft i n the bearing to ensure that the oil tube is straight.

11. Support the bearing plate using suitable wooden blocks. Position the blocks across the bearing housing aperture to act as assembly stops.

12. Press in the bearing until flush with the bearing plate.

13. Press in the primary pinion. Check that the bearing remains flush with the bearing plate.

14. Fit the retaining plates and serrated bolts.

15. Fit the shim washer and circlip.

16. Measure the clearance between the circlip and the shim washer. There must be a clearance of

0,05 mm (0.002 in) maximum.

17. If required, adjust the clearance by fitting a replacement shim washer. Shim range is 2,O to

2,15 mm (0.079 to 0.085 in) in 0,05 mm (0.002 in) stages.

ST 1 240M

7. Withdraw t h e bearing retaining plates and serrated bolts.

8. Press out the primary pinion bearing.

18. Fit the bearing plate assembly.

19. Fit the front cover and oil pump assembly.

20. Fit the bell housing.

LT 95 FOUR SPEED GEARBOX

1371

, . ~

. .

..-.

REMOVE AND OVERHAUL THE MAINSHAFT

ASSEMBLY

Special tool:

1861388 - extractor for mainshaft spacer and gear

1. Remove the bell housing.

2. Rcmove the front bearing plate.

3. Remove the main gearchangc sclectors.

4. Removc the mainshaft rear bearing housing and roller bearing.

5. Remove the bottom cover from the transfer gearbox.

NOTE: At this stage in the dismantling, on early gearboxes only, it is necessary to remove the transfer top cover selector finger and shaft. On later gearboxes the cross-shaft is machined to enable the spacer to be completely withdrawn. Also the main shaft spacer and transfer gear are secured by Loctite 275 to the main shaft.

6. Remove the snap-ring, shim washer and mainshaft transfer gear, using special tool 18G1388.

1 I . Withdraw the mainshaft assembly, allowing the first-speed gear to remain behind to avoid fouling on thc casing.

12. Lift out the first-speed gear.

I.!

"4.

.;::"

7. Fit extractor 1861388 to transfer gear spacer.

8. Withdraw the spacer along the mainshaft until the larger diameter on the spacer reaches the transfer gear lever cross-shaft.

9. Withdraw the spacer through thc machined scollop.

10. When the spacer is free on the mainshaft removc the extractor.

13. Refit thc first-speed gear, scalloped thrust washer, thrust needle bearing and stepped thrust washer, stepped face outwards.

14. Withdraw the mainshaft spacer.

ST1246M

LT 95 FOUR SPEED GEARBOX

Overhaul mainshaft assembly

Dismantle

15. Withdraw thc first-speed gear, thrust washers and roller bearings from the rear of the shaft.

16. Remove the snap-ring and shim washer from thc front of the shaft.

17. Lift off the third/fourth gears synchromesh assembly.

18. Withdraw the third and second-speed gears and the associated thrust washers and needle-rollcr bearings.

19. Dismantle the third/fourth gears synchromesh assembly, first pushing down the sliding blocks to free the synchromesh balls from the retaining groove in the outer member.

2'1

Assemble

22. Replacement thrust washers and roller bcarings must not be degreased.

23. Lubricate all items before assembly, iising clcan main gearbox oil.

24. Fit the oil seal to the mainshaft front end.

Assemble synchromesh units

25. Fit together the thirdfourth gcar synchromesh outer and inner members, outer member coned face toward inner member plain face.

26. Fit the sliding blocks, radius face outward.

27. Locate the springs through the sliding blocks into the housing bores in the inner member.

28. Position the balls on thc spring ends; press home in sequence and retain by hand.

29. Lift the outer member to retain the balls. Continue lifting until the balls spring home into the annular groove in the outer member.

30. Assemble the first/second gear synchromesh unit in the manner dcscribed for third/fourth gear unit. Fit the outer member coned face toward the front end of the mainshaft.

Assemble mainshaft front end

31. Fit a synchromesh cone to the f i r s t k c o n d gcar synchromesh outer member.

32. Position a chamfered thrust washer, a thrust needle bearing and a scalloped thrust washer on the mainshaft.

33. Fit a radial needle bearing and the second-speed gear.

ST1247M

20. Dismantle the firsthecond gears synchromesh assembly in a similar manner, particularly noting their position for refitting.

21. Withdraw the oil scal from the Sore in the mainshaft front end.

-2w

ST1249M

ST 1248M

' r

,':

.:'

34. Fit a scalloped thrust washer, a thrust needle bearing and a further scalloped thrust washer.

35. Fit a radial needle bearing and the third-specd gear.

36. Fit a scalloped thrust washer, a thrust needle bearing and a further scalloped thrust washer.

37. Position a synchromesh cone onto the third-speed gear.

38. Fit the synchromesh unit, coned face to rear.

LT95 FOUR SPEED GEARBOX

137

Assemble mainshaft rear end

46. Fit a synchromesh cone to the first/second gear synchromesh outer member.

47. Position a chamfercd thrust washer, a thrust needle bearing and a scallopcd thrust washcr on the mainshaft.

48. Fit the first-speed gear and bearing.

49. Fit a scalloped thrust washer, a thrust needle bearing and the stepped thrust washcr, stcppcd face outwards.

50. The mainshaft spacer, transfer gear, shim washer and snap-ring are fitted during mainshaft refitting.

ST1253M

Set end-float of gears

39. Position the mainshaft asscmbly vertical, front end uppermost.

40. Apply a light loading on the gears to remove end-float.

41. Position the snap-ring in the mainshaft groove.

42. Measure the distance between the snap-ring lower edge and the synchromesh unit inner member.

43. Select a shim to reduce the measured clearance to

0,025 to 0,150 mm (0.001 to 0.006 in) when fitted.

44. Shim range is 1,85 to 2,45 mm (0.073 to 0.096 in) in 0,15 mm (0.006 i n ) increments.

45. Fit the selected shim washer and the snap-ring.

Assemble mainshaft assembly to gearbox

51. Position the gearbox with the R.H. side rfownwar& to .id refittifin

52. Remove the gearbox side cover.

53. Temporarily move the first-speed gear toward the rear of the shaft.

54. Offer the assembled mainshaft to the gearbox and manoeuvre the first-speed gear past the reverse idler gear.

137

LT 95 FOUR SPEED GEARBOX

55. Engage the shaft into the main bearing.

56. Engage the first/second gear synchromesh outer member and the reverse idler gear.

57. Push the mainshaft home enough to allow the mainshaft spacer to be locatcd on the rear end, with the spacer larger diameter forward of the transfer gear lever cross-shaft.

65. Temporarily remove the snap-ring and the mainshaft transfer gear.

66. Slide back the mainshaft spacer as far as the transfer gear lever cross-shaft will allow.

67. Apply a thin coating of Loctite 275 grade to the exposed area of the mainshaft.

68. Push home the mainshaft spacer.

69. Fit the mainshaft transfer gear.

70. Fit the previously selected shim washer and secure with the snap-ring.

71. Fit the bottom cover to t h e transfer box using a new joint washer and evenly tighten the fourteen retaining bolts to the correct torque.

72. Fit the mainshaft rear bearing housing and roller bearing.

73. Assemble the main gearchange selectors to the gearbox.

74. Fit the front bearing plate.

75. Fit the bell housing. fl

....+I e ; v

58. Re-position the first-speed gear, thrust washers and thrust needle bearing correctly on the mainshaft.

59. Push the mainshaft fully home, ensuring that t h e thrust washers and needle bearing remain correctly located against the first-speed gear.

60. Move the mainshaft spacer along thc shaft, and into t h e oil seal, to abut the main bearing.

61. Temporarily fit the mainshaft transfer gear.

62. Position thc snap-ring in the groove in the mainshaft.

6 3 . Hold the mainshaft fully to the rear and measure the clearance between the snap-ring and the transfer gear.

64. Select a shim washer to allow 0,050 mm (0.002 in) maximum clearance between the snap-ring and transfer gear when fitted. Shim range 1,8 to

2,O mm (0.071 to 0,079 in) in 0,OS mm (0.002 in) increments.

REMOVE AND OVERHAUL LAYSHAFT BEARINGS

Special tools:

R01004

18G284 extractor layshaft rear bearing outer member

18G47

- - layshaft bearing inner members

1. Remove the bell housing.

2. Remove t h e front cover and oil pump assembly.

3. Remove the main gears selectors.

4. Remove the front bearing plate assembly.

5 . Remove the mainshaft assembly.

6. Press out the layshaft front bearing outer member from t h e front bearing plate. gy..

ST 1256M

...

*:,

"... 1

..,;

7. Extract t h e layshaft rear bearing outer member from the gearbox casing, extiaetor 186284 and adaptor 18G284AR.

LT 95 FOUR SPEED GEARBOX 37

12. Press t h e rear bearing outer member into t h e gearbox casing.

13. Enter the front bearing outer member into the front bcaring plate. D

O not fit fully in at this stage.

ST1259M

I J

8. Withdraw the bearing inner members from the layshaft. Extractor 18647 press and 18G47BA col tars. n

14. Remove the primary pinion from thc bearing plate.

15. Position the layshaft in the gearbox casing.

16. Temporarily fit the front bearing plate and joint washer.

17. Press in the front bearing outer member until thcrc is no end-float on the layshaft and no cnd-load on the bcarings.

18. On the bearing outer member position a shim washer of a thickncss suitable to stand 0,25 m m

(0.010 in) approximately proud of the front bearing plate. This shim thickness may be subsequently adjusted depending on the amount of bearing pre-load i t affords.

19. Temporarily remove the oil pump top cover and withdraw the pump drive gear.

20. Temporarily fit the front cover and new joint washer to the bearing plate. Ensure that the shim washer remains in position.

ST 1258M

Check bearing pre-load

8. Repiacement bearings inner and outer membcrs are supplied as matched pairs and not as separate items.

10. The replacement bearings must not be degreased.

Before fitting, lubricate with correct grade gearbox oil. Refer to lubrication chart.

11. Press the bearing inner members onto thc layshaft. c

LT 95 FOUR SPEED GEARBOX

21. Measure the rolling resistance of the layshaft, using a spring balance and a cord coiled around the layshaft larger diameter. The rolling rcsistance must be 7 to 3,38 k g (6 to 7.5 Ibs).

REMOVE AND OVERHAUL DIFFERENTIAL LOCK

ACTUATORASSEMBLY

1. Remove the four bolts and withdraw the assembly from front output shaft housing.

2. Remove the detent spring and ball.

22. To adjust the pre-load, fit a replacemcnt shim or suitable thickness to the front bearing outer member. Shim range is from 1,55 mm (0.059 in) to

2,510 mm (0.098 in) in 0,05 mm (0.002 in) increments.

23. When the pre-load is satisfactory, remove thc front cover assembly.

24. Remove the front bcaring plate.

25. Fit the primary pinion.

26. Fit the oil pump cover and drive gear.

27. Fit the front bearing plate assembly.

28. Assemble the selectors for the main gears.

29. Fit the front cover and oil pump assembly.

30. Fit the bell housing.

Dismantle and overhaul assembly

3. Remove thc differential lock warning switch and washers.

4. Drive out the retaining pin.

5 . Remove the actuator fixings.

6. Withdraw the actuator and shaft.

7. Withdraw the '0' ring seal.

8. Withdraw the joint washer.

9. Fit a new '0' ring seal to actuator shaft.

10. Coat both sides of the joint washer with Hylomar

PL32M.

11. Fit the actuator and shaft and secui-c to the housing.

12. Fit thc actuator shaft retaining pin.

13. Fit the diffcrential lock warning switch and washers.

Assemble to gearbox

14. Fit the ball and detent spring.

15. Apply Hylomar PL32M jointing compound to both sides ot a new actuator housing joint washer.

16. Fit and secure the assembly to the gearbox and evenly tighten the four retaining bolts.

LT 95 FOUR SPEED GEARBOX 37

Renew

3 . Engagc reverse gear.

4. Connect the electrical leads to t h e switch.

5 . Switch the ignition ‘ON’.

6. Screw in the switch, less shim washers, until the switch contacts are madc.

7. Screw in a further half turn.

8. Mcasurc the clearance bctwcen the switch lower face and the gearbox.

9. Select shim washers to suit the clearance. Shim thicknesses are 0,5 m m (0.020 in) and 0,127 m m

(0.005 in).

10. Fit the sclected shim washcr(s) and switch. Tighten to a torque of 1,4 to 2,0 kgf m (15 to 20 Ibl lt) (20 to 27 Nm).

Renew

3 . Start the engine and move the differential lock vacuum control valve to the ‘up’ position.

4. Connect the elcctrical leads to the actuator switch.

5 . Screw in the switch, less shim washers, until the switch contacts are made.

ST 1265M

6. Screw in a further half turn.

7. Measure the clearance between the switch lower face and the housing.

8. Select shim washers to suit the clearance. Shim thicknesses are 0,5 mm (0.020 in) and 0,137 m m

(0.005 in).

9. Fit the selected shim washcr(s) and the switch.

10. Re-position control valve and stop engine.

LT 95 FOUR SPEED GEARBOX

RENEW REAR OUTPUT SHAFT OIL SEAL

Remove

1. Disconnect the rear propeller shaft at the transmission brake.

\ ' \

Renew

7. Press in the oil seal, open face first, until the seal plain face just clears the chamfer on the seal housing bore.

8. Fit the oil shield, which must be a close f i t on the speedometer housing.

9. Fit the oil catcher, applying Bostik compoiind 771 to seal the oil catcher against the brake back plate.

10. Fit the transmission brake drum complete with rear coupling flange.

11. Fit the oil seal washer and locking nut and tighten to the correct torque.

12. Connect the rear propeller shaft to the transmission brake.

ST1266M

2. Remove the locking n u t , washer and the felt oil seal.

3 . Withdraw t h e transmission brake drum complete with rear coupling flange.

4. Remove the oil catcher.

5. Prise off the oil shield.

6. Withdraw the oil seal.

RENEW FRONT OUTPUT SHAFT OIL SEAL

Remove

1. D~~~~~~~~~ front propeller shaft.

2. Remove the coupling flangc locknut and washer.

3 . Withdraw the coupling flange complete with mudshicld.

4. Withdraw the oil seal.

ST1267M

STl268M

Renew

5 . Fit thc oil seal, lip side Icading.

6. Fit the flange coupling with mudshield.

7. Secure the flange with locknut and washer and tighten to the correct torque.

8. Connect the propeller shaft.

/-:.

LT85 FIVE SPEED GEARBOX

REMOVE LTWLT230T MAIN GEARBOX AND Cradle for removing gearbox

TRANSFER BOX

The gearbox should be removed from underneath the vehicle, using a hydraulic hoist, as illustrated; a cradle for locating the gearbox on to thc hoist can be manufactured to the drawing below. If a similar cradle was made for the LT77 gearbox, it can be modified to suit both the Ll77 and LT85 gearboxes by making the modifications shown by the large arrows.

Manufacture a cradle to t h e dimensions given in the drawing and attach it to a transmission hoist. To achieve balance of the transmission unit when mounted o n the transmission hoist, it is essential that point A is situated over thc centre of thc lifting hoist ram. Drill fixing holes R to suit hoist table. Secure the transmission unit to the lifting bracket at point C, by mcans of the lower bolts retaining t h e transfer gearbox rear cover.

Refer to the Removal instructions for the LT77 gearbox page 1. The method for removing the LT8Y

LT230T gearbox assembly is similar, except for the following.

1. It is not necessary to remove the engine fan cowl.

2. Remove the air cleaner.

3. Remove thc highhow selector housing from the transfer box.

4. Use t h e cradle and hydraulic hoist already described, to remove the gearbox.

ST1547M

8.75

1.0 x 1.0 x 0.13

NOTE: It may be necessary to remove the transmission brake drum to allow removal of the gearbox assembly.

5.0

3.0

76 .O

1 f

0.25

ST 538M

102.0

508.0

MATERIAL A N D WELDING SPEClFlCATlON

Steel

Tu be

Plate BS 1449 (Grade 4 or 14)

BS 4848 (Part 2 )

Arc Welding BS 5135

A V A N T

VORDER

ANTERIORE

LT85 e

= MODIFICATION

)371

LT85 FIVE SPEED GEARBOX

OVERHAUL LT85

FIVE SPEED GEARBOX

- Ninety and One Ten V8 models

Service Tools:

18G 1294 - Guide studs

18G 1400 -Two legged puller

1% 1431 -

MS 284 -Slide hammer

MS 550 -

LST 101 - Gauge, first gear end float

LST 102

LST 284-1

LST 550- I

Remover-Replacer, mainshaft rear oil seal

- front bearing roller

LST 550-2 - bearing outer track

LST 550-3 front and rear bearing

LST 1431-1

- mainshaft

In addition to the above Service Tools, the following five items should be manufactured locally to facilitate dismantling and reassembly of the gearbox.

ST1369M

Selector detent spring retaining tool and spaccrs.

A - up from washers

ST1476M

Spacer for retaining layshaft rear bearing

ST1371M

ST1475M

Spacers for retaining front bearing plate. Two required.

A -This dimension must be more than 12 mm.

Gauge for reverse cross-over lever adjustment.

LT85 FIVE SPEED GEARBOX

137

. . .

ST1321M

Stand for securing the gearbox in a vice

A. 11 mm diameter holes

R . Make from 50 m m x 6 m m stcel angle

C. Make from 6 mm steel plate

D. 10 mm diameter bolt with hexagonal head

E. 10” nuts

MATERIAI, AND WELDING SPECIFICATION

Steel Plate BS 1449 (Grade 4 or 14)

Arc Welding BS 5135

LT85 FIVE SPEED GEARBOX

GEAR CASINGS

1. Bell housing and clutch release assembly

2 . Oil pump assembly

3 . Front bearing plate

3 . Main gear case

5 . Oil filter assembly

6. Gear change lever assembly

7. Extension housing m

GEAR SELECTORS

1. Selector rails

2. Selector fork assembly for 5th gear

3. Selector arm for reverse gear

4. Selector fork for 1st and 2nd gear

5. Reverse gear cross-over lever assembly

6. Selector fork for 3rd and 4th gear

7. Selector jaws

. ..

. . . ..

..,

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LT85 FIVE SPEED GEARBOX

L-

A--

LT85 FIVE SPEED GEARBOX 37

I ' l . I

Mainshaft first speed gear running clearance

Mainshaft third spccd gcar running clearance

Mainshaft fifth speed gear running clearancc

Input shaft bearing running clcarance

GEARBOX DATA

0,075 mm maximum

0,075 m m maximum

0,075 mm maximum

DISMANTLING

1. Ensurc gearbox oil has bcen completely drained.

2. Position gearbox on bench and support with suitable wooden block.

3. Remove four bolts and detach L.H. gearbox mounting bracket.

4. Remove extension housing and gasket.

5. Fit manufactured stand to gearbox and secure with two bolts, nuts, spring and plain washers. Adjust bolt under filter housing as necessary.

Bias spring housing and gear lever

10. Remove four bolts and spring washers and lift bias spring housing from gearbox.

11. Remove bias springs and shims. Care should be taken w h e n removing lower shims to avoid them slipping under gear lever pivot bar and into gearbox.

12. Removc bias spring housing gasket.

13. Remove gear lever, complctc with gaitcr and nylon cup.

ST1322M

6. With assistance, fit gearbox and stand into a suitable vice and firmly sccurc.

7. Removc six bolts and washers and lift bcll housing, complctc with clutch release lever, sleeve and thrust bearing, lrom gearbox.

8. Remove bell housing gasket.

9. Fit two bell housing fixing bolts, with spacers to front bearing plate. c

ST 1318M

ST1323M

Gearbox top cover

14. Remove reverse light switch, if fitted.

15. Remove breather pipe banjo union fixing bolt.

16. Remove eight bolts and spring washers and lift top cover and breather pipes from gearbox.

17. Remove detent springs.

18. Remove top cover gasket.

LT85 FIVE SPEED GEARBOX

Selector rails and forks

19. Using a suitable magnet withdraw the selector rail detent balls from drillings in gearbox. If detent balls arc tight leave operation until after selector rails have been withdrawn, when the detcnt balls can be pushed down into the selector rail borc, then removed.

20. Release reverse gate spring from knock-over lever and remove from reverse gear rail.

21. Raise knock-over lever and tap down reverse jaw roll-pin until jaw is free on rail.

22. Remove clamp bolt from reverse cross-over lever and withdraw reverse selector rail and jaw from gearbox.

23. Remove split pin washer and clevis pin securing 5th gear selector rail to selector fork and bracket asscmbiy.

24. Push selector rail forwards and tap down 5th gear jaw roll pin until jaw is free on rail.

25. Withdraw 5th gear selector rail and j a w from gearbox.

26. Remove clamp bolt from 3rdi4th selector fork and move selector rail forward.

ST1324M

..: z..:'.

27. T a p down 3rd/4th jaw roll pin until jaw is free on

. . _ j i

' selector rail.

28. Withdraw 3rd/4th selector rail and jaw.

20. Remove interlock from 3rd/4th sclcctor rail.

30. T a p down lst/2nd jaw roll pin until .jaw is free on sclector rail.

31. Remove clamp bolt from Isti2nd selector fork and withdraw lst/2nd selector rail and j a w .

32. Remove interlock from lst/2nd sclcctor rail.

33. Lift rcverse cross-over lcvcr rrom gearbox.

34. Remove 1st/2nd and 3rd/4th selector forks.

LT85 FIVE SPEED GEARBOX 37

36. Remove two bolts, spring washers and plain washers securing 5th gear fork and bracket assembly to gearbox. Do not displace selector fork slipper pads when removing fork.

Kevcrsc idlcr shaft, mainshaft and layshaft

37. Remove circlip, selective washer, oil seal collar and

'0' ring from mainshaft.

35. Remove interlock plungers and also dctcnt balls if not removed in operation 19.

ST1328M

STI

I I

ST1329M

38. Remove 5 t h gear synchro hub and baulk ring.

39. Remove 5th gear, spacer, needle roller bcaring and thrust washer.

ST1330M

LT85 FIVE SPEED GEARBOX

43. Disengage 1st and 4th gears.

44. Remove two socket hcad set screws and two bolts with spring washers and remove reverse shaft and layshaft bearing track retaining plate.

4.5. Remove reverse lcver pivot bolt and l i f t reverse lever from gearbox.

7..::.

’*

40. Remove mainshaft rear bearing circlip.

41. Release stake nut collar from recess in layshaft, remove stake nut and 5th gear from layshaft.

NOTE: To facilitate this operation lock gearbox by engaging both 1st and 4th gears.

ST1334M

ST1332M e

46. Fit extractor adaptor Tool N o . LST 284-1 to reverse idler shaft.

47. Fit slide hammer Tool N o . MS 284 to adaptor and withdraw reverse idler shaft from gcarbox. Reverse idler gear and thrust washer will drop into bottom of gearbox.

48. Kcmove seven bolts and spring washers and withdraw front cover and gasket from front bearing plate.

42. Fit manufactured spaccr to layshaft to retain rear bearing and secure in position with stake nut finger-tight only

$3:

. ..;, a&&.

49. Remove layshaft front bearing spacer.

50. Remove input shaft bearing circlip and selective washer.

51. Remove bolts and spacers retaining front bcaring plate to gearbox.

LT85 FIVE SPEED GEARBOX I37 I

5 0

58. Extract mainshaft from rear bearing. To facilitate operation assistance will be needed to support mainshaft and layshaft.

59. T a p layshaft forwards and remove rear bearing race.

60. Withdraw mainshaft and layshaft assemblies.

61. Remove rcvcrsc idler gear and thrust washer from gearbox.

ST1336M

52. Fit plates and spacers of' Tool N o . LST 1431-1 to front bcaring plate with 90 mm bolts.

53. Locate two legged puller Tool N o . 18G 1400 as shown and remove front bcaring plate from input shart and gearbox.

NOTE: Centre bolt and lcgs of puller must be aligned squarely with input shaft.

52,

OVERHAUL

Main gearbox case

1. Remove drain plug.

2. Remove retaining plug and oil filter.

3. Remove filler/level plug.

4. Remove interlock cross drilling plug.

ST1337M

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D y m n . r p ha.,&na7

. \ L . I I I " * b " b U 1 1 1 1 6

I y . I c . L y t

Y1ULb 6 U J R " ' .

55.

56.

Remove stake n u t and spacer from layshaft.

Fit plates and spacers of Tool No. LST 1431-1 to rear of gearbox with 95 mm bolts in top locations

57. and 90 mm bolts in lower.

Locate two legged puller Tool N o . 18G 1400, again ensuring centre bolt and legs of puller are aligned squarely.

5. Remove top cover location dowels and 5th gear fork bracket dowels, if necessary.

6. Remove gearbox stand.

LT85 FIVE SPEED GEARBOX

7. Position gearbox on suitable wooden blocks and remove mainshaft rear bearing using Tool Nos.

LST 550-3 and MS 550.

12. Clean mainshaft and layshaft bearing seatings.

13. Clean rcverse gear idler shaft seating, drain plug, and level/filler plug tappings.

14. Using an air line blow out filter plug tapping and oil-way, detcnt and interlock seatings.

15. Clean top cover facc and 5th gear fork bracket dowels.

16. Hcat gearbox case to facilitate fitting of mainshaft rear bearing and layshaft bearing track.

17. Fit circlip to mainshaft rear bearing.

18. Position rear bearing in gearbox seating.

19. Using Tool Nos. LST 550-3 and MS 550 tap rear bearing into position.

8. Remove rear bearing circlip and clcan.

9. Using Tool Nos. LS'T 550-2 and MS 550 remove layshaft rear bearing outer track.

NOTE: Use rounded end of tool.

1 9 1

20. With gearbox still warm fit layshaft rear bearing outcr track using Tool Nos. LST 550-2 and MS 550.

21. Refit interlock drilling plug.

22. Refit lcvel/filler plug

- n o t tighten at this stage.

23. Refit oil filter and retaining plug using new copper washer.

24. Refit magnetic drain plug and new copper washer. z;:.,,

STl34 M

10. CIea earbox case asket faces, in erior and exterior and inspect for cracks and obvious signs of damage etc.

11. Clean magnetic drain-plug, oil filter retaining plug, level/filler plug and oil filter.

ST1343M

Front bearing plate

1. Support front bearing plate on suitable wooden blocks as shown.

2. Using Tool Nos. LS'I' 550-3 and MS 550 remove input shaft bearing.

LT85 FIVE SPEED GEARBOX 37

9. Using Tool No. 550-1 fit layshaft bearing, with

6,5-7 mm of bearing protruding from front of bearing plate. This allows easier assembly of the layshaft and mainshaft at a later stage.

. 2

ST1344M

3. Remove circlip from bearing.

4. Remove layshaft front bcaring from bearing plate using Tool N o . LS'I'550-1.

ST1347M

10. Fit circlip to input shaft bearing.

11. With the front bearing plate still warm fit input shaft bearing, using Tool Nos. LST 550-3 and MS

550.

ST1345M

5 . If necessary, replace bearing plate dowels.

6. Clean bearing plate, gasket forces and input shaft and layshaft bearing seatings.

7. Using an air line blow out oil-way in bearing plate.

8. Heat front bearing plate to facilitate refitting of input shaft and layshaft bearings.

ST1346M

LT85 FIVE SPEED GEARBOX

Front cover and oil pump

1. Remove cover plate, drive gear and impellor gear.

2. Remove cover plate ‘0’

3. Position wooden blocks under front cover and remove oil feed ring and oil seal.

Gearbox extension housing

1. Remove rear oil seal from extension housing using suitable drift.

2. If necessary, replace extension housing dowels.

3. Clean gasket faccs and interior and extcrior surfaces.

4. Using Tool No. LS7’ 102 fit new oil seal to ex t e n sio n ho usi ng .

ST1348M

4. Clean all front cover componcnts.

5. Lubricate lip o f new oil seal and position in front cover seating with close side downwards.

6. Fully seat oil seal in position using suitable tube.

7. Fit oil feed ring, ensuring the three holes of the feed ring are at the bottom and the ccntrc hole is aligned with the mating oil pump feed drilling in the front cover.

6 .

Fully scat feed ring in position using suitable tube.

9. Fit cover plate ‘0’ fit impellor gear, and drive gear.

10. Fit cover plate, ensuring chamfer of centre hole is facing towards oil pump. l o p Cover

1. Clcan top cover gasket faccs and interior and exterior surfaces.

2. Remove top filler plug, clcan, apply sealant and refit plug.

Bias spring housing and lower gear lever

1. Fit housing to vice and remove bias spring adjusting Screws

1 r d

STl350M

2. Clean lower gear levcr and nylon cup.

3. Clean housing, adjusting screws, bias spring bores,

4. springs and shims.

Refit bins spring screws - turns only at this stage.

_-. w:

“$1’

LT85 FIVE SPEED GEARBOX

1371 f.

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. . .

7 ,

Bell housing

1 . Remove clip retaining thrust bearing carrier to clutch opcrating lever f o r k .

2. Withdraw thrust bearing and carrier assembly from sleeve.

3. Remove bolt and spring washer securing operating lever pivot clip to lever. Remove pivot clip.

4. Remove operating lever and pivot slotted washer.

5. Remove operating lever pivot.

6. Unscrew single bolt and remove bearing sleeve from bell housing. lstl2nd synchro assembly

Before dismantling

1. Before dismantling, mark relationship of synchro hub to sleeve.

2. Fit synchro baulk rings.

3 . Place synchro assembly and baulk rings into a plastic bag t o ensure none of the components are lost during next operation.

4. Press sleevc from hub.

STl351M

7. Rcmovc bearing sleeve dowels, if necessary.

8. Clean bell housing interior, exterior and mating faces.

9' grease to lever pivot and inner face

O f bearing carrier.

10. Reassemble in rcverse order.

Input shaft

1. Remove 4th gear baulk ring and needlc roller bearing.

2. Clean all components, ensuring oil-way on input shaft is blown through with air line.

3. Clcan input bearing circlip and selectivc washer.

Mainshaft

1. Remove shim and 1st gear bush.

2. Remove 1st gear, needle roller bearing and bearing

3. spacer.

Remove 1st gear baulk ring, lst/2nd gear synchro assembly and 2nd gear.

4. Remove 2nd gear baulk ring, 2nd gear, needle roller spacer and needle roller bearing.

5 . Fit mainshaft into vice and remove circlip retaining

3rd/4th synchro hub and gear assembly.

6. Remove selective washer, 3rd/4th synchro assembly and baulk ring.

7. Remove 3rd gear, needle roller spacer and needle roller bearing.

8. Remove oil seal from front of maimhaft.

9. Clean mainshaft, and all mainshaft components and check for obvious wear. Ensure oil-ways in mainshaft are blown through with air line.

ST1352M

5. Retrieve synchro balls, springs and slipper pads and remove baulk ring.

6 . Clean all synchro assembly components.

NOTE: Before reassembling the synchro assembly, carry out the checks for 3rd and 2nd gear end floats, as described in the following paragraphs under the heading

'Mainshaft and gear train'.

7. Fit synchro hub to sleeve ensuring the alignment marks match up.

8. Place hub and sleeve over suitable block.

9. With hub resting on block adjust height of hub sufficiently to f i t springs.

10. Locate slipper pads, fit springs and press balls down to be retained by synchro sleevc.

11. Fit baulk ring to hub and sleeve.

ST1477M

12. Invert synchro assembly, carefully, and fit second baulk ring.

13. Press synchro sleeve over hub to locate balls in position.

14. Remove baulk rings.

LT85 FIVE SPEED GEARBOX

3rdl4th synchro assembly

1. Repeat operation as for IstRnd synchro assembly

(omitting the gear end float checks).

NOTE: When reassembling 3rd/4th synchro the large chamfer on synchro slceve faces the small boss on the hub,

5th gear synchro assembly

I . Repeat operation as for Ist/2nd synchro assembly.

NOTE: When reassembling 5th gear synchro the chamfer on the hub faces to the rear.

Mainshaft and gear train

3rd gear end float

1. Locatc the main shaft in a vertical position as shown. Fit 3rd gear and needle roller bearing to the shaft and replace the 3rdl4th synchro inner member. Press down on the synchro inner member and check thc gear running clearance with a feeler gauge, as shown. A clearancc in excess of 0,19 mm

(.U08 in) indicates that the thrust laces arc w c r n and may be the cause of gear noise or transmission back lash. New or little worn components will usually have a clearance of between 0,075 mm and

0,125 mm (.003 in to .OM in).

STl354M

Next fit the original selective washer and retain with the circlip. Check the clearancc between the washer and the synchro hub which must not exceed

0,075 mm (.U03 in). The condition is ideal when the selective washer can be just turned by hand, i.e. minimum end float. Finally secure components with a new circlip.

Oil seal

3. Renew oil seal in the front of the main shaft at this stage then invert the shaft ready f o r assembly of the rear end.

2nd gear end float

4. Fit 2nd gcar needle roller bearing, spacer, 2nd gear and synchromesh inner member with thc selector groove towards the rear as shown. Press down on the synchro inner member and check 2nd gear end float tolerance which is identical to 3rd gear previously described.

3rdl4th synchro end float

2. Maintain the mainshaft in a vertical position as shown. Fit 3rd gear needle roller bearing, spacer,

3rd gear, baulk ring and synchromesh with the large area thrust face towards 3rd gear and the chamfer on the outer member towards thc front.

ST1539M

I I

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1371 i.;

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1st gear to bush end float

5. To carry out 1st gear check, it is not necessary to assemble the components on to the mainshaft.

Assemble 1st gear on to the bush and using a suitable straight edge or flat plate (the oil pump back plate is ideal) check the end float of 1st gear on the bush as shown. The tolerance is identical to

3rd and 2nd gear end floats.

5th gear end float

7. Fit 5th gear thrust washer, 5th gear, needle bearing and spacer followed by synchromesh unit but leaving out the baulk ring at this stage. Press down on the synchro inner member and chcck the gear end float as shown; this tolerance, again is identical to 3rd gear.

S7 -1 540M

. . .

. l s t h d synchromesh end float

6. fit the 1st gear baulk ring, 1st gear bush and gear, original selective washer, dummy bearing

LST 101 and circlip onto the shaft, then check the end float as shown. Choose a suitable selcctivc shim washer to obtain the correct tolerance which is identical with 3rd/4th synchromesh, i.e. minimum to 0,075 mm (.U03 in).

5th gear synchro end float

8. Fit the 5th gear synchromesh backing plate, seal collar, original selective shim washer and circlip.

Then check the clearance as shown; select a

I his adjustment is identical to the lst/2nd and

3rd/4th synchromesh units.

With all t h c mainshaft adjustments correct, remove the 5th gear componcnts ready for assembly.

STl353M

-6

5th gear selector fork and bracket assembly

1. Remove slipper pads from selector fork and check for wear.

2. If necessary, remove circlips and remove selector fork pivot pins.

3. Clean all componcnts and refit in reverse order.

LT85 FIVE SPEED GEARBOX

Lay shaft

1. Remove layshaft rear bearing inner race.

2. Fit layshaft to vice and lever off front bearing inner track.

REASSEMBLING GEARBOX

Input shaft, mainshaft and layshaft

1. Position front bearing p!ate on suitable stand and fit input shaft into bearing.

3. Clean layshaft, bearings and tracks and check for wear.

4. Fit layshaft front bearing track.

5. Fit rear bearing race to layshaft, ensuring the identification numbers etc., of the bearing are facing forwards.

NOTE: Inner tracks are offset and the bearings must be fitted with narrow shoulders together.

Reverse idler gear assembly, shaft and lever

1 Secure reverse gear i n vice and iemove circlip retaining bearings

S'I

2. Secure bearing plate in vice, fit original selective washer and retain with circlip.

3. Measure the clearance between washer and input shaft bearing. If a measurcmcnt in excess of

0,075 mm is obtained remove circlip and washer.

STl359M

2. Remove upper thrust washer, two needle roller bearings and lower thrust washer.

3. Invert reverse gear and remove second circlip.

4. If necessary, - spiit piin and withdraw siipper pads and washer from reverse gear lever.

5 . Press out reverse lever cross link operating pin, if necessary.

6. Clean all components and check for wear.

7. Lubricate needle roller bearings and reassemble reverse idler gear assembly and lever in reverse order.

ST1357M

3 . Selcct and measure new washer to takc up the excessive running ciearance.

5. Fit n e w selective washer and retain with circlip.

6. Recheck to ensure a running clearance of

0,075 mm is obtained between washer and bearing.

7 . Position front bearing plate on suitable stand.

8. Lubricate mainshaft pilot bcaring and fit to input shaft.

9. Fit 4th gear baulk ring to input shaft.

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. .

10. Lower mainshaft assembly into input shaft at the same time rotating t o engage baulk ring slots and lugs.

I 1. Engage 3rd gear.

12. Fit layshaft assembly to front bearing plate and mesh with mainshaft.

NOTE: Take care to ensure that the front layshaft bearing rollers are not put out of alignment, then return 3rdl4th synchro hub to neutral.

LT85 FIVE SPEED GEARBOX 37

15. Fit guide studs 18G 1294 t o gearbox. i a

-1 2

ST1361M

ST1358M

. . '

13. Remove the rear bearing circlip and dummy bearing.

Reverse gear

14. Fit thrust washer to reverse gear, chamfer towards gear, locate gear in gearbox case, and retain temporarily in position with a screwdriver, or similar implement.

Gearbox case and reverse shaft

16. Fit new gasket on front bearing platc.

17. Lower gearbox case over mainshaft/layshaft asscmblics using guide studs to locate front bearing plate.

18. Fit tube, Tool No. LST 1431-1 over mainshaft and locate on rear bearing.

19. Fit Tool No. 18G 1431 over mainshaft and locate on other tool.

20. With assistance, to prevent gearbox and mainshaft rotation, and using above tools, pull gearbox to front bearing plate.

/I7

@ J

ST1362M

LT85 FIVE SPEED GEARBOX

21. Fit layshaft rear bearing (identification numbers to rear) dummy spacer, and rctain temporarily with layshaft n u t .

22. Remove guide studs 18G 1294.

23. Temporarily fit two bell housing bolts with spacers, to secure front bearing plate to gearbox.

24. Remove Tool Nos. 18G 1431 and LST 1431-1 and then check that t h e mainshaft is engaged through bearing sufficiently to fit mainshaft bearing circlip.

25. Remove screwdriver from reversc shaft location and f i t reverse shaft.

35. Ensure oil pump drive aligns with the square seating in the layshaft and fit front cover to front bearing plate and secure with seven bolts and spring washers.

36. Removc tape from input shaft splincs.

Reverse lever, reverse shaft/bearing retaining plate

37. Fit reverse lever to reverse gear.

38. Apply Loctite Stud and Bearing Fit (270) to pivot bolt threads, fit bolt in gearbox and locate in reverse lever pivot boss.

39. Position reverse shaft, layshaft bearing track retaining plate and secure top of plate with two bolts and spring washers.

26. Invert gearbox and fit spacer to layshaft front bearing.

27. Using Tool Nos. LS’I‘ 550-1 and MS 550 locate layshaft front bearing to final position.

ST1364M

28. Temporarily remove layshaft bearing spacer.

29. Refit gcarbox stand (manufactured tool) to underside of gearbox and secure with two bolts, nuts, spring and plain washers. Adjust bolt undes filter housing as necessary.

30. Secure gearbox stand in vice.

31. Check that 4th gear baulk ring and all other baulk rings are free.

32. Fit layshaft front bearing spacer.

33. Fit new gasket to front cover.

34. Tape input shaft splines, to prevent damagc to front cover oil seal in next operation.

40. Apply Loctite Stud and Bearing Fit (270) to socket head set screws and secure bottom of retaining plate.

5th gear, layshaft and mainshaft

41. Remove nut from layshaft and remove dummy spacer.

42. Fit 5th gear to layshaft with large boss to the rear.

43. Rotate layshaft to give access to stake slot.

44. To facilitate next operation, lock gearbox by engaging 1st and 4th gears.

45. Fit a new 5th gear retaining nut and tighten to the specified torque.

46. Stake retaining n u t collar into recess in layshaft.

47. Return 1st and 4th synchros to neutral.

48. Fit mainshaft rear bearing circlip.

49. Fit thrust washer.

50. Lubricate needle roller bearings and fit to mainshaft followed by spacer and 5 t h gear.

51. Fit 5th gear synchro cone and synchro hub assembly.

52. Tape mainshaft splincs and f i t ‘0’ to its seating on mainshaft.

53. Fit oil seal collar and locate in peg on hub backing plate.

54. Fit the washer selected during the 5th gear end float check and retain with circlip.

55. Remove tape.

LT85 FIVE SPEED GEARBOX

1371

Selector rails and forks

56. Locate 5th gear fork and bracket on to synchro hub and gcarbox dowels.

57. Secure fork bracket to gearbox with two bolts, plain washers and spring washers.

59. Fit l s t n n d and 3rd/4th selector forks.

58. Fit selector rail intcrlock plungers into t h e cross- drilling in the gcarbox case.

60. Fit reverse cross-over lever.

61. Insert interlock into l s t / h d selector rail.

LT85 FIVE SPEED GEARBOX

62. Push M 2 n d selector rail through gearbox seating and locate in reverse cross-over lever and selector fork; do not tighten fork clamp bolt.

NOTE: IstiZnd fork clamp bolt is not a set boit.

63. Fit lst/2nd selector jaw to rail and align for roll pin.

64. Using suitable drift, tap in roll pin to secure jaw and rail.

65. Repeat operation for 3rd/4th selector rail and jaw.

66. Push 5th gear selector rail through gearbox scating and locate in reverse cross-over lever.

67. Fit 5th gear selector jaw to rail, align for roll pin.

68. Locate selector rail into 5th gear selector fork and secure with clevis pin, washer, and split pin.

69. Fit roll pin and secure selector rail and jaw.

70. Push reverse sclector rail through gearbox scating and locate in reverse cross-over. lever clamp bolt.

Do not lighten

71. Fit jaw to rail and align for roll pin.

72. Using a suitable drift, fit roll pin to secure sclccror rail and jaw.

NOTE: The roll pin must be inserted sufficiently to be flush with the underside face of the selector.jaw.

72 71

ST 1367M

LT85 FIVE SPEED GEARBOX

137

I w

:::.

, ::,:+,

,..

.<:,!?

.,...:I.

73. Fit reverse gate spring to selector rail and knock- over Ievcr.

74. Fit detent balls and springs.

Selector fork adjustment

75. Fit top cover gasket.

76. Secure detent spring retaining tool and spacers to gearbox using two 8 x 50 m m bolts and plain washers.

Reverse cross-over lever adjustment

The purpose of the following adjustment is to ensure that when 1st gcar is selected the outer member of the

Ist/2nd synchro mcmber is not also engaged with the reverse idler.

84. Move reverse gear thrust washer fully forward.

85. Fit gauge (manufactured tool) to selector shaft.

86. Move rail rearwards and select reverse gcar.

87. Move cross-over lever rearwards to lightly nip gauge between reverse gear and thrust washer.

88. 'Tighten reverse cross-over lever clamp bolt and return rail to neutral. Remove gauge.

89. Move l s t k n d rail rearwards and select first gear.

Ensure a minimum clearance of 1,0 mm has been obtained between reverse gear idler and reverse gear on lst/2nd synchro sleeve.

If

there is not enough clearance, readjust the reverse cross-over lever.

90. Return lst/2nd rail back to neutral.

91. Remove detent spring retaining tool and spacers.

ST1368M

77. 'Tighten bolts and compress detent springs until retaining plate contacts the two spacers.

78. Ensure that 1st/2nd selector rail and synchro slccve arc in neutral position. Tighten clamp bolt sufficiently to eliminate a n y rock in the selector fork and move selcctor fork rearwards.

79. Scribc a pencil line on rail at rear of fork yoke.

80. Movc fork forwards on rail and scribe line on rail at rear of fork yoke.

81. Scribe a line midway between the other lincs on the selector shaft.

82. Move selector fork to centre line.and tighten clamp bolt.

83. Repeat operation for 3rd/4th sclcctor fork and rail.

Gearbox top cover

92. Fit top cover and locate over detent springs.

93. Position breather pipe, locate retaining clips and secure top cover and breather pipe clips with eight bolts and spring washers.

94. Fit breather pipe banjo union and fibre washers.

95. Fit reverse light switch.

96. Place clean rag in top cover to prevent entry of dirt etc.

1351

LT85 FIVE SPEED GEARBOX

Bell housing

97. Remove bolts and spacers securing front bearing plate to gearbox.

98. Fit new bell housing gasket.

99. Locate bell housing squarely on dowels and secure housing and front bearing plate to gearbox with six bolts and spring washers.

Lower gear leverlbias spring housing

100. Removc rag from gearbox top cover.

101. Lubricate gear lever ball and lower yoke.

102. Fit lower gear lever, nylon cup and grommet.

103. Fit new gasket to housing.

104. Grease bias springs.

105. Carefully fit shims and bias springs, followed by spring housing and secure with four set screws, and spring washers.

106. Remove gearbox assembly from vice and detach

-stand.

Gearbox extension housing

107. The special nut retaining the 5th gcar t o the layshaft must be secured in position, by carefully forming the collar of the n u t into the layshaft slots, as illustrated.

CAUTION: A round nose tool must be used for this operation to avoid splitting the collar of the nut. Also, the 5th laygear should be supported by a wooden block when the nut is being deformed, to prevent damage to the bearings adjacent to the gear.

108. Support underside of gearbox with wooden block.

109. Lubricate oil seal protection sleeve Tool No. LST

102 and fit to oil seal from inside extension housing. ilG. Fit new gasket to extension housing.

11 I . Carefully manoeuvre extension housing over mainshaft and position squarely on dowels.

112. Remove oil seal protection sleeve.

113. Secure extension housing to gearbox with eight bolts, spring washers and single n u t .

NOTE: Illustration shows correct bolt lengths and their locations in extension housing.

60"

45"

ST1374M

40"

ST1483M a4

;.i

...

,,.-

3rd/4th gear selector rail adjustment

114. Slacken 3rd/4th stop screw in extension housing.

LT85 FIVE SPEED GEARBOX

1371

Bias spring adjustment

123. Apply Loctite Stud and Bearing Fit (270) to bias springs screws and tighten up until screw heads are flush with top face of bias spring housing.

123

115. Select 3rd gear.

116. Tighten stop screw until it makes contact with

3rd/4th selector rail.

117. Turn back stop Screw one turn. Retighten locknut.

118. Return gear lever to neutral.

119. Slacken locknut o n 3rd/4th stop bolt inside bell housing.

Gearbox mounting

124. Refit mounting to extension housing and secure with four bolts.

ST1376M ‘ \

120. Unscrew stop bolt.

121. Select 4th gear and screw in stop bolt until contact is made with 3rd/4th selector shaft.

122. Turn back stop bolt one turn and rctighten locknut.

Return gear lever to neutral.

LT230T TRANSFER GEARBOX

REMOVE LT230T TRANSFER GEARBOX

FROM

THE

LT85 GEARBOX

Special tool: 18G 1425 - Guide studs (3)

Also, locally manufactured adaptor plate, see below

Adaptor plate for removing transfer gearbox

The transfer gearbox should be removed from underneath the vehicle, using a hydraulic hoist. An adaptor plate for locating the transfer gearbox onto the hoist can be manufactured locally to the drawing below. If a similar adaptor plate was made for the

Lr230R transfer gearbox, it can be modified to suit both the LT230R and LT230T gearboxes by making the modifications shown by the large arrows. rl i

ARC WE,LD TO BS5135

13 9.7

I 1

12.63 67.0 12.63 6 x 0 )

165.1

-4-3

0.56 I

;r--...----,

6.43

Material. Steel plate BS 1449 Grade 4 or 14

Holes marked thus

* to be drilled to fit hoist being used.

$ = MODIFICATION

LT230T TRANSFER GEARBOX

I37 I

1 . Install the vehicle on a ramp.

2. Disconnect thc battery.

3. Remove the cover panel from the right-hand seat base.

4. Remove the breathcr pipe union from the transfer gearbox high/low cross-shaft housing.

5. Disconnect the high/low lever.

16. Remove three nuts and bolts securing the right- handgearbox mounting bracket to the chassis, then remove the n u t from the rubber mounting and withdraw the bracket.

17. Place a suitable wooden block between the indin gearbox and chassis cross-member, then lower the hoist until the gearbox contacts the wooden block.

18. Disconnect the electrical lead from thc differential lock switch.

19. Move the small crank lever, for the highhow selector, upward to allow access to the adjacent n u t securing t h e transfer box to t h e main gearbox

20.

21. extension case.

Remove t h e two nuts and four bolts securing the transfer box to t h e main gearbox extension case.

Fit three guide studs, 18G 1425, through the transfer box bolt holes to support i t during

22. removal.

Lower the hoist and withdraw the transfer box from the vehicle.

. .. ..

6. Disconnect the transmission brake cable at the clevis joint.

7. Raise the vehicle on the ramp and drain the oil from the transfer box.

8. Remove the centrc section of the exhaust system.

9. Disconnect the f r o n t and rear propeller shafts from the gearbox and move them aside.

10. Disconnect the speedometer cable from the transfer gearbox.

11. Remove the split pin at the lower end of the pivot arm for the differential lock control. Then, rcmove the two bolts securing the pivot arm to allow the link to be disconnected.

12. Manufacture an adaptor plate in accordance with the drawing, to attach to the gearbox hoist and transfer box to facilitate removal (RR244M).

13. Place four, 30 mm (1.250 i n ) long spacers between the top ef the hoist and the adapter p!ate at the securing points and secure the adaptor plate to the hoist.

14. Remove the four central bolts from the transfer box bottom cover, move the hoist into position and secure the adaptor plate to the transfer box.

15. Adjust the hoist to take the weight of the transfer box.

Refitting

23. Make sure that the joint faces of the transfer box and main gearbox extension case are clean and that the three guide studs, 18G 1425, arc fitted to the extension case.

24. Lubricate t h e oil scal in the joint face of transfer box, secure the transfer box to the adaptor plate on t h e lifting hoist and raise the hoist until the transfer box can be located over the guide studs.

25. Remove the guide studs and secure the transfer box to the main gearbox extension case. Tighten the nuts and bolts to t h e corrcct torque.

26. Complete t h e refitting procedurc by reversing the removal sequence, noting the iollowing important points.

27. After removing the lifting hoist and adaptor plate from t h e transfer box, clean the threads of the four bolts for the transfer box bottom cover, coat them

\,xdjth Lectitc 290, 2nd fit them tegethcr with snrinu washers. Tighten to the correct torque.

28. Refill the transfer box with the correct grade oil to the oil level plug hole.

29. Check, and if necessary top up, the oil level in the main gearbox. Use the correct grade oil.

30. Check the operation of the handbrake and adjust as necessary.

LT230T TRANSFER BOX

LT230T TRANSFER BOX 37

*...,

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,. ....

LT230T TRANSFER GEARBOX OVERHAUL

Service Tools:

18G47-7 - replacer

18G47RB-1

Adaptor centre differential bearing remover

18G47BB-3 remover button

18G257 -

18G1205 - Prop flange wrench

18G1271 -Oil seal remover

1861422

1861423 - remover/replacer

18G 1424

MS47 - Hand press

MS550 -

LST104 - Intermediate gear dummy shaft

LST105 -

LST550-4 -

TRANSFER BOX DATA

Front bevcl gcar end-float . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear end-float . . . . . . . . . . . . . . . . . . . . . . . . . .

Rcar output housing clearance . . . . . . . . . . . . . . . . . . . . .

High range gear end-float . . . . . . . . . . . . . . . . . . . . . . . . .

Front differential bearing prc-load . . . . . . . . . . . . . . . . . .

Input gear bearing pre-load . . . . . . . . . . . . . . . . . . . . . . . .

Intermediate shaft bearing pre-load . . . . . . . . . . . . . . . . .

0,025 to 0,075 mm (0.001 to 0.003 in)

1,OO mm (0.039 in)

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

1.36 to 4.53 kg (3 to 10 Ibs)

2.26 to 6.80 kg (5 to 15 Ibs)

1.81 to 4.53 kg (4 to 10 Ibs)

Transmission brake removal (if not previously removed)

1. Remove two countersunk screws and withdraw brake drum.

2. Remove four bolts securing the brake back-plate; the two bottom fixing retain the oil catcher.

NOTE: An hexagonal type socket should be used for these bolts.

Bottom cover removal

3 . Rcmove the six bolts and washers retaining thc bottom cover.

4. Remove the gasket and bottom cover.

LT230r BOX

Intermediate shaft and gear cluster removal

5 . Release stake nut from recess in intermediate shaft and remove stake nut and discard.

6. Unscrew the single bolt and remove anti-rotation plate at the rear face of the transfer box.

10. Remove taper roller bearings and bearing spacer from the intermediate gear cluster assembly.

7. Tap the intermediate gear shaft from the transfer box.

ST1574M

Power take-of cover removal

11. Remove six bolts and washers retaining the take- off cover and speedo cable clips.

12. Remove the gasket and cover.

// f-- ,

8. Lift out the intermediate gear cluster and bearing assembly .

9. Remove the ‘0’ shaft and from inside the transfer box.

Input gear removal

13. Remove t h e two countersunk screws and detach t h e main shaft bearing housing.

14. Remove the gasket.

15. Withdraw t h e input gear assembly.

16. Prise out and discard the oil seal at the front of the transfer box casing using service tool 1861271.

17. Drift out the input gear front bearing track.

$Ti x .J

ST1576M

Highhow cross-shaft housing removal

18. Remove the six bolts and washers retaining the cross-shaft housing and earth lead.

19. Remove thc gasket and cross-shaft housing.

LT230T TRANSFER BOX

1371

Rear output housing removal

23. Remove six bolts and washers and dctach the rear output housing and shaft assembly from the transfer casing.

24. Remove the gasket.

S T I 577M

Front output housing removal

20. Remove the eight bolts and washers and detach t h e output housing from the transfer box casing, taking care not to mislay the dowel.

Centre differential removal

21. Remove high/low selector shaft dctent plug, spring and retrieve the ball with a suitable magnet.

Transfer case overhaul -

25. Remove the studs and dowels.

26. Remove the magnetic drain plug and fi!ler!level

22. Withdraw the centre differential and sclcctor shaft/ fork assembly. ST1581M

LT230T TRANSFER BOX

27. Drift out differential rear bearing track.

28. Clean all areas of the transfer casing ensuring all traces of “Loctite” are removed from faces and threads.

Transfer case overhaul -

29. Fit studs and dowels to front face of t h e transfer casing .

NOTE: The position of the radial dowel blade is set in line with the circle which is formed by the front output housing fixing holes.

30. Refit magnetic drain plug with new copper washer and tighten t o the specified torque, loosely f i t the filler/level plug.

3 . Remove speedo-drive housing. This can be prised out with a screwdriver.

4. Remove housing from the vice and drift out the output shaft, by striking the flange cnd of the shaft.

5 . Carefully prise off thc oil catch ring using a screwdriver in the slot provided.

Rear output housing overhaul -dismantling flange wrench 1861205 and socket spanner, remove the flange nut, steel and felt washers.

Ensure flange bolts are fully engaged in the wrench.

2. Remove output flange with circlips attached. If necessary, use a two-legged puller.

NOTE: The circlip need only be released if the flange bolts are to be renewed.

6. Prise out and discard the seal from the output housing using tool 1SG1271.

7. Using circlip pliers 18G2.57, rcmovc the circlip retaining the bearing.

ST1588M

37 LT230T TRANSFER BOX

20. Slide drive gear and spacer on to the output shaft.

21. Locate output shaft into the bearing in t h e housing and drift into position.

22. Locate speedometer gcar (driven) housing assembly into the output housing and press in until flush with the housing face.

5. Remove the high range gear and bush, taking care not to disturb the high/low sleeve.

Mark

the relationship of the high/low sleeve to the hub and then remove the sleeve.

7. Using a suitable press behind thc low range gear carefully remove the high/low hub and low range gcar.

ST1640M

Centre differential unit overhaul -dismantling

1. Secure centre diffcrential unit to a vice fitted with soft jaws, and release stake nut from recess.

2. Remove stake nut using tool 1831423 and suitablc socket wrench.

3. Removc thc diffcrential unit from the vice.

4. Secure hand press MS47 in vice with collars

18G47BB and using button 1847BB/3 rcmove the rear taper bearing and collars.

ST1593M

8. Substituting collar LST47-1 remove front taper roller bearing.

9. Remove hand press from the vice.

10. Using soft jaws secure the differential unit in the vice by gripping the hub splines.

ST1592M

STl596M

\ll Y I

LT230T TRANSFER BOX

(.,.

....

: '

11. Remove the eight retaining bolts and lift off t h e front part of the differential unit.

12. Release t h e retaining ring and remove front upper bevcl gear and thrust washer.

13. Rcmove the pinion gears and dished washers along with the cross shafts.

14. Remove the rear lower bevel gear and thrust asher from the rear part of the differential unit.

22. Measure t h e front upper bevel gear thrust washer and note the thickness.

23. Fit the thrust washer and bevel gear to the front unit.

24. Refit the retaining ring and front differential unit, aligning the two engraved arrows marked on both halves of the unit.

25. Fit four bolts equi-spaced and torque to the correct figure.

114

25-

S T 1

15. Remove thc rear differential unit from thc vicc and clean all components; examine Tor wcar o r clamage and renew if necessary.

16. Clean all components; examine for wear o r damage and renew if necessary.

17. Using soft jaws secure the rear differential unit in the vice by gripping the hub splincs.

IS. Ensure that all differential components arc dry to assist i n checking end-float.

19. Using a micrometer, measure one of the bevel gear thrust washers and note the thickness.

20. Fit the thrust washer and bevel gear to the rear lower differential unit.

21. Assemble both pinion asscmblies and dished washers on to their respective shafts and fit to the rear differential unit.

26. Mcasure the front bevel gear end-float with fcclcr gaugcs through the slots provided in the front differential unit. The end-float must be 0,025 to

0,075 mm (0.001 to 0.003 in) maximum. When measuring use two sets of feelcr gauges, one on each side of the front differential unit. This will give a true reading of the end-float.

137 I

LT230T TRANSFER BOX

27. Invert the differential unit and repeat operation 26 for the rear bevel gear end-float.

28. Invert the differential unit and secure in vice and remove the four bolts and lift off the front differential unit.

29. Remove the rctaining ring, bevel gear and the washer and both pinion assemblies.

30. Select the correct thrust washers required for final assembly.

Reassembling

31. Fit the selected thrust washer and bevel gear into the rear lower differential unit.

32. Assemble both pinion assemblies and dished washers o n to their respective shafts and fit the rear differential unit. Secure t h e assemblies with the retaining ring.

33. Lubricate all the components.

34. Fit the selected thrust washer and bevel gear into the front upper differential unit.

'1 602

38. Fit the low range gear, with its dog teeth uppermost to the differential assembly.

39. Prcss the highllow hub on to the differential spli nes.

40. Slide the high/low selector sleeve on to the high/ low hub ensuring that t h e alignment marks are opposite each other.

41. Fit the bush into the high range gear so that the flange is fitted o n the opposite side o f the gear to thc dog teeth. Slide the bushed gear on to the differential assembly with the dog teeth down.

35. Align both units as previously described and secure with the eight bolts t o the specified torque.

36. Finally check that the differential gears rotate freely. Locate the front differential bearing onto the front, upper differential shaft and press into position using larger end of tool 1861424 as shown.

37. Invert the differential unit and secure in the vice.

NOTE: During the following sequences all parts should be lubricated as they are fitted.

ST1599M

LT230T TRANSFER BOX

. - -

,,,:~,:~~.

!.,E

....

42. Locate the rear differential bearing on to the hub and press it into position using the smaller end of

48. Fit the new selector fork with its boss towards the three detent grooves. Align the tapped hole in the tool 18G1424. fork boss with the indent in the shaft nearest to the

43. Fit the stake n u t and tighten to the specified torque using tool 18G1423.

44. Check the cnd float of the high and low rangc gears

0,05 to 0,15 nim (0.002 to 0.005 in).

NOTE: If the clearances vary from those specified detent grooves.

49. Apply Loctite 290 to the set screw threads and fit the set screw and tighten to the specified torque. in the data, the assembly must be rebuilt using the relevant new parts.

1 .

.. ,

ST1605M

ST1603M

45. Peen the stakc n u t collar by carefully forming the collar of the n u t into thc slot a s illustrated.

CAUTION: A round nose tool must be used for this operation to avoid splitting the collar of the nut.

Centre differential rear bearing track

50. Fit the differential rear bearing track 1,OO mm

(0.039 in) below t h e outer facc of casing using a suitablc tool as shown.

~ ~~

1 .OO mm (0.039

ST1604M

46. Clean and check high/low selector fork assembly for wear and renew i f necessary.

47. To renew the selector fork remove the square set screw and slide thc fork from the shaft.

ST1606M

Rear output housing -

I . Grease output housing gasket and position on to the rear facc of thc transfer box casing.

LT230T TRANSFER BOX

2. Fit output housing and ensure clearance of

1.00 mm (0.039 in) between housing face and gasket.

3. Fit the six output housing bolts with Loctite 290 on t h e threads, with washcrs and tighten evenly to the correct torque, which will pull the rcar bcaring into position.

4. Apply Loctite 290 to decent plug; fit and locate, by screwing gently fully home and then unscrewing two turns.

ST1594M

Centre differential unit refit

1. Fit the sclcctor forkhhaft assembly to the high/low selector slecvc on the differential assembly, with detent groove to the rear of the differential asscm bly .

2. Locatc the differential assembly complelc with selector fork into t h e transfer box casing. I t may be necessary t o rotate the output shaft to ease fitment, and engage selector shaft into its hole.

Front output housing overhaul -

1. Unscrew seven retaining bolts and washcrs and remove the differential lock sclector side cover and gasket.

2. Unscrew thrce retaining bolts and washers and lift the differential lock finger housing and actuator assembly from the front output housing.

3. Slackcn the locknut and unscrew the differential lock warning light switch.

4. Rcmovc selector shaft dctent plug, spring and ball using a suitable magnct.

5 . Compress the selector fork spring and remove the two spring retaining caps.

ST1607M

3. Fit selector shaft ball and spring through the side of the transfer box casing.

100

4.: d L

6. Withdraw the selector shaft from the rear of the output housing.

7. Remove the selector fork and spring through the side cover aperture.

8 Remove lock-up sleeve from the rear of the output housing.

LT230T TRANSFER BOX

137

15. Invert housing and drift out bearing from inside the case as shown.

,..;;

A ”

9. Using flange wrench 18G1205 and socket wrench, remove the flange n u t , steel and felt washers.

NOTE: Ensure that flange bolts are fully engaged in the wrench

10. Remove the output flange with oil seal shield.

NOTE: These parts need not be separated unless the flange bolts are to be renewed.

11. Drift output shaft rearwards from housing using a soft headed mallet.

12. Slide off the collar from the output shaft

16. Drift out centre differential front taper roller bcaring track and shim.

17. Drift out selector shaft cup plug from housing.

18. Clean all components ensuring all traces of

“Loctite” are removcd from faccs and threads.

19. Examine components for wear or damage and renew if necessary.

NOTE: Renew oil seal and felt seal and flange nut.

.:.::.

13. Prise out and discard oil seal from output housing using service tool 1861271.

14. Remove circlip with circlip pliers 186257.

101

LT230T TRANSFER BOX

Keassem bling

20. Press the bearing into the housing; do not use excessive force. To facilitate fitting the bearing, hcat the front output housing. (This is not to exceed 1 OOOC).

21. Using circlip pliers 186257, fit the bearing retaining clips.

22. Fit a new oil seal (open side inwards) using replacer tool 18G1422, until the seal just makes contact with the circlip.

23. Carefully charge the lips of the seal with clean grease.

24. Slide collar on to the output shaft, with its chamfered edge towards the dog teeth.

25. Fit the output shaft through the bearing and drift home.

29. Grease and fit new gasket and locate the front output housing on t h e transfer box casing.

30. Secure housing with the eight retaining bolts and washers, the upper middle bolt being longer than the rest. Do not tighten the bolts at this stage.

31. Engage high or low gear.

32. Check t h e rolling resistance of the differential using a spring balance and a length of string wound around the exposed splines of the high/low hub.

33. With the correct shim fitted the load to turn should be 1.36 kg to 4.53 kg (3 Ibs to 10 Ibs). This applies to new or used bearings. (New bearings will register at the top end and used bearings will register at the low end.

34. If the reading is in excess of the above measurements, remove the front output housing assembly from the transfcr box casing.

35. Using a suitable cxtractor, withdraw the centre differential bearing track and change the shim for one of a suitable thickness. ( A thinner shim will reduce the rolling resistance).

36. Fit the new shim and drift t h c differential bcaring track back into its housing until fully home.

37. Having obtained the load to turn, prop-up the transfcr box casing on the bench with the front face uppermost.

~ 5 ' 3

I ' L

C-'

ST1614M

Adjusting front differential bearing pre-load

26. Measure original differential front bearing track shim.

27. Refit original shim into input housing.

28. Drift differential f r o n t bearing track into thc housing.

ST1616M

38. Apply Loctite 290 to the threads of the housing rctaining bolts and fit the eight bolts and washers into the front output housing and secure to transfer box casing.

39. Fit front output flangc, felt washers, steel washers and flange nu!.

40. Using flange wrench 1861205 and torque wrench pull t h e output shaft up to the correct position.

Check that the oil seal shield does not foul the housing.

NOTE: Ensure that the flange bolts are fully engaged in the wrench.

&:; ...i et::;/'

102

LT230T TRANSFER BOX

46. Compress the spring between t h e fork lugs and slide the retaining caps o n to the shaft ensuring the spring is captured with the “cupped” side of the caps.

47. Drift selector shaft sea! cup into position.

41. Repeat the above operation for the rear output flange.

48. Fit selector shaft dctcnt ball and spring in the tapped hole on top of t h e output housing.

40. Apply Loctite 290 to detent plug threads. Screw detent plug gently homc and then unscrew two turns.

42. Compress the selector shaft spring and fit to the selector fork.

:i, ;:. 43. Locate selector fork through front output housing

.I side cover aperture, ensuring that the fork engages in the groove of the lock-up sleevc.

44. Fit selector shaft through the aperture in the front of the output housing and pass i t through t h e sclector fork lugs and spring into the rear part c.f the housing.

45. Rotate the selector shaft until the two flats for the spring retaining caps are at right angles to the side cover plate face.

Differential lock finger housing overhaul -

1 . Unscrew and discard t h e “nyloc” nut and remove the operating lever and washer.

2. Remove t h e pivot shaft from lock finger housing.

3. Remove the ‘0’ rings from the pivot shaft and housing and discard.

4. Clean all components; examine for wear or damage and renew if necessary.

Reassembling

5 . Fit new ‘0’ rings on to pivot shalt and lock finger housing and lubricate with oil.

6. Locate the pivot shaft in t h e housing.

103

LT230T TRANSFER BOX

7. Fit the differential lock lever over the pivot shaft so that the lever will face forward with the bcnd upwards. This lever is then i n the correct operating position.

S. Retain the lever with a plain washer and new nyloc nut.

High/low cross-shaft housing overhaul

1. Remove t h e selector finger grub screw and withdraw the cross-shaft from the cross-shaft housing and remove the selcctor finger,

2. Remove the ‘0’

3. Drift out selector housing cup plug if necessary.

4. Clean all the components and chcck for damage or wear, replace if necessary.

5 . Apply sealant to a new cup plug and fit so that the cup is just below the chamfcr for the cross-shaft bore.

7. Lubricate the shaft and insert into the cross-shaft housing.

8. Fit selector finger ensuring that it aligns with the recess in the cross-shaft.

9. Apply Loctite 290 to the grub screw and secure the selector finger to the cross-shaft and fully tighten to thc specified torque.

ST1618M

9. Fit the differential lock finger housing into its seating

On the front output housing, ensuring ( h a t the selector finger is located in the flat of the selector shaft.

10. Apply Loctitc 290 to thc bolt threads and retain thc lock finger housing with the three bolts and washers to the specified torque.

10. Grease and fit the high/low selector housing gasket on the front output housing.

11. Fit high/low cross-shaft housing, ensuring that the selector finger locates in the slot of the selector shaft, and secure with six bolts and washers to the specified torque. n/ r;

-es!

ST1619M

1 04

ST1646M

Input gear overhaul -dismantling

1 . Clean the input gear assembly and examine for wear or damage. Remove the bearings only if they are to be renewed.

.,:

:,,.

2. Secure hand press MS47 in the vice and using collars 18G47-7 and button l8G47-BB/3, remove rear taper roller bearing from input gear assembly.

3. Invert input gear assembly in hand press and remove front taper roller bearing.

4. Clean input gear.

LT230T TRANSFER BOX

..,

Reassembling

5 . Position rcar taper roller bcaring on input gear and using hand press MS47 and collars 18647-7 press the bearing fully homc.

6. Invert input gcar and fit the front taper roller bearing using t h e press and collars.

9. Reposition transfer box casing so the front face is uppcrmost and f i t oil seal (open sidc inwards) using replacer tool 18G1422.

7. Prop up the transfer box casing on the bench with the rear face uppermost.

8. Drift in the front taper bearing track.

10. Lubricate both bearings with clean oil.

11. Fit the input gear assembly into the transfer box casing with the dog teeth uppermost.

105

LT230T TRANSFER BOX

Checking input gear bearing pre-load

12. Secure bearing support plate in the vice. Drift out input gear bcaring track, and remove shim.

13. Clean hearing support plate and shim. Measure original shim and note its thickness.

14. Fit the original shim to the support plate.

15. Locate the bearing track in the support platc and press fully home.

22. Remove the spring balance, string and service tool.

23. Remove the six bolts and the bearing support plate.

24. Drift out the input gear bearing track from the support plate and discard original shim.

25. Select t h e correct size shim to obtain a load to turn of 2.26 kg to 6.80 kg (5 Ib to 15 Ibs).

26. Fit shim to support plate, locate bearing track and press home.

27. Fit bearing support platc and secure to transfer box casing with the six bolts (do not tighten).

28. Repeat the rolling resistance check as previously described, and note the value obtained.

Intermediate gear assembly overhaul

1. Drift out intermediate gear bearing tracks

2 . Remove circlips.

16. Apply grease to the gasket and f i t on to the transfer box casing.

17. Fit the bearing support platc on to the transfer box casing and secure with the six bolts, but do not tightcn.

18. Fit the servicc tool LST105 to input gear and engage the spline.

19. Tie a length of string to the split pin and f i t i t to the service tool as shown.

20. Attach a spring balance to the string and carefully tension the spring until a load to turn t h e input gear is obtained. A pull of 2.26 kg to 6.80 kg (5 Ib to

21.

15 Ibs) is required.

If the reading obtained is outside t h e above limits, the original shim must be changed.

ST1628M

3. Clean all intermcdiate gcar components and lock plate. Check for damage o r wear and replace as

4. necessary .

Fit new circlips into the intermediatc gcar cluster.

5. Using tools LST5.50-4 and MS550 fit bcaring tracks

106

L ~ 2 3 0 T BOX

137

,L;!-: 6. Fit the '0' rings to t h e intermediate shaft and into the intermediate shaft bore at the front of the transfcr box casing.

13. Turn the intermediate shaft to allow fitting of retaining plate.

14. Fit retaining plate and secure with retaining bolt and washer.

15. Fit thc intcrmediate gear shaft retaining stake nut.

.. z . .

'.,..

. .

. . . . .

Intermediate gear reassembly

7. Check for damage to the intermcdiate shaft thread and if neccssary clean up with a fine file or stone.

8. Lubricate the taper roller bearings and

I intermcdiate gear shaft.

9. Insert new bearing spacer to gear assembly, followed by t h e taper roller bearings.

..;.:I

.,,

ST1649M

10. Fit dummy shaft LST104 into the intermediate gear cluster.

11. Locate the gear assembly into the transfer box casing from the bottom cover aperture.

12. Insert intermediate shaft from the front of the transfer box casing, pushing the dummy shaft right through as shown and remove. (Making sure that the intermediate gear cluster meshcs with the input

Adjusting intermediate gear torque-to-turn

16. Select neutral.

17. Fit service tool LSTlO5 to input gear and cngagc spline.

18. Tic a length of string to a split pin and f i t to the service tool as shown. Attach thc spring balance to the string.

19. To obtain the correct figures and to collapsc thc spacer within the intermediate gear cluster, tighten the intermediate shaft nut until the load-to-turn has increased by 3.7 kg (7 Ibs) 5 1.63 kg (F 3 Ibs) on that noted when checking input shaft load-to-turn.

The torque to tighten the retaining nut will be approximately 203 Nm (150 Ib ft).

20. Peen t h e stake n u t by carefully forming the collar of the nut into the intermediate shaft recess, as illustrated.

CAUTION: A round nose tool must be used for this operation to avoid the collar of the nut.

'..,...

'I: ,:.

. i

107

LT230T TRANSFER BOX

Power take-off cover

21. Clean power take-off cover and gasket facc.

22. Fit the two countersunk screws and tighten.

23. Remove ihe six bolis from the bearing support plate.

24. Apply sealant to the cover plate gasket and fit it to the bearing support plate.

25. Apply Loctitc 290 to bolt threads and secure the power take-off cover with the six bolts and washers.

Bottom cover -

26. Clean bottom cover and gasket face.

27. Apply sealant to cover gasket and fit to transfer box casing.

28. Apply Loctite 290 to bolt threads and secure the bottom cover with six bolts and washers.

+ -

STl634M

6. Disconnect the battery and m o v c the dirfercntial lock lever to t h e left to disengage differential lock.

7. Clean thc front output housing side cover.

8. Grcase and fit side cover gaskct.

9. Apply Loctite 290 to bolt threads, fit side cover and secure with sevcn bolts and washers.

Differential lock switch adjustment

1. Select differential locked position by moving the lock taper towards the right side of the transfer box

2. casing.

Apply sealant to the diffcrential lock warning light switch and fit to the top of the front output housing.

3. Connect a test lamp circuit to the differential lock

4. switch.

Screw in the lock switch until the bulb is illuminated.

5. Turn in the switch another half a turn and tighten with the locknut against t h e housing.

Transmission brake -

NOTE: Under certain circumstances it is better to fit the transmission brake assembly after being installed in the vehicle.

1. Clcan brake backplate and oil catcher and apply sealant to the catcher joint face.

2. Locate brake backplate on the rcar output housing with the brake operating lcver o n thc right side of the transfer box casing.

3. Secure the backplatc (including the oil catcher) with the four special bolts and tighten using

21 hexagonal socket to the specified torque.

4. Clean and fit brake drum and secure with two countersunk screws.

,. .;” OVERHAUL PROPELLER SHAFTS

. .

Dismantle

1. Remove the propeller shaft from the vehicle

2. If a gaiter encloses the sliding member release the two securing clips. Slide t h e gaiter along the shaft to expose the sliding member.

3. Note the alignment markings on the sliding member and the propeller shaft. Sec note following instruction 22.

PRO PELLER S HAFTS

147

6. Remove paint, rust, etc. from the vicinity of the universal joint bearing cups and circlips.

NOTE: Before dismantling the propeller shaft joint, mark the position of the spider pin lubricator relative to the journal yoke ears to ensure that the grease nipple boss is re-assembled in the correct running position to reduce the possibility of imbatance.

7. Remove the circlips, and grease nipple.

STlOOOM

4. Unscrew the dust cap and withdraw the sliding member.

S T l 00 3 M

8. Tap the yokes to eject the bearing cups.

9. Withdraw the bearing cups and spider and discard.

10. Repeat instructions propeller shaft.

5 to 8 at opposite end of

11. Thoroughly clean the yokcs and bearing cup locations.

STlOOlM

5 . Clean and cxamine the splines for wear. Worn splines or excessive back-lash will necessitate propcller shaft renewal.

S T 1 0 0 4 M

ST1002 M

PROPELLER SHAFTS

Assemble

12. Remove the bearing cups from the new spider.

13. Check that all needle rollers are present and are properly positioned in the bearing cups.

14. Ensure bearing cups are one third full of fresh lubricant. See Lubrication chart.

15. Enter the new spider complete with seals into the yokes of the sliding member flange. Ensure that the grease nipple hole faces away from the flange.

16. Partially insert one bearing cup into a flange yoke and enter the spider trunnion into the bearing cup taking care not to dislodge the needle rollers.

17. Insert the opposite bearing cup into the flange yoke. Using a vice, carefully press both cups into place taking care to engage the spider trunnion without dislodging the needle rollers.

18. Remove the flange and spider from the vice.

19. Using a flat faced adaptor of slightly smaller diameter than the bearing cups press each cup into its respective yoke until they reach the lower land of the circlip grooves. Do not press the bearing cups below this point or damage may be caused to the cups and seals.

22. Lubricate the sliding member spines and fit the sliding member to the propeller shaft ensuring that the markings on both the sliding member and propeller shaft align.

NOTE. The Universal joints on the front propeller shaft are, by design, not assembled in-line with one another. Nevertheless, the alignment marks on the sliding member and propeller shaft must coincide when assembling.

23. Fit and tighten the dust cap.

24. Fit the grease nipples to the spider and the sliding member and lubricate.

25. Slide the gaiter (if fitted) over the sliding member.

26. Locate the sliding member in the mid-position of its travel and secure the gaiter clips. Note that the gaiter clips must be positioned at 180" to each other so that they will not influence propeller shaft balance.

I - rJ

ST1005 M

20. Fit the circlips.

21. Engage the spider i n the yokes of the sliding member. Fit the bearing cups and circlips as described in instructions 15 to 20.

ST 1007M

27. Apply instructions 15 to 20 to the opposite end of the propeller shaft.

28. Fit the grease nipple and lubricate.

29. Fit the propeller shaft to the vehicle.

ST1006M

REAR DIFFERENTIAL -

. .,

I1 ye,

OVERHAUL REAR AXLE DIFFERENTIAL

ASSEMBLY

(option)

Service tools:

18G 1205 flange holder tool;

18G 191 pinion height setting gauge;

18G 191-4 universal setting block;

18G 47-6 pinion head bearing removerlreplacer;

18G 1382 oil seal replacer;

RO 262757A extractor for pinion bearing caps;

RO

262757-1 replacer - use with RO 262757A;

RO 262757-2 adaptor tail bearing cap replacer;

RO 530105 spanner bearing nuts;

RO 530106 bracket for dial gauge and indicator;

MS 47 press

7. Remove the split pin securing the pinion flange nut.

8. Remove the pinion flange n u t using service tool

18G 1205, to rcstrain the flange.

DISMANTLE

It is essential that differential components are marked in their original positions and relative to other components so that, if refitted, their initial setting is maintained. Note that the bearing caps must not be interchanged.

9. Withdraw the pinion complete with pinion head bearing and outer bearing shims. Withdraw the shims.

10. Remove the pinion flange oil seal, spacer and bcaring. Discard the oil seal.

1. Remove the differential assembly from the axle.

2. Drift out the roll pin securing the bearing nut locking fingers to the bearing caps. Remove the locking fingers.

3. Slacken the bcaring cap bolts and mark t h e caps for reassembly.

4. Using service tool R O 530105, remove the bearing adjusting nuts.

5. Remove the bearing cap bolts and bearing caps.

6. Lift out the crown wheel, differential unit and bearings.

ST506M

11. Using service tool R O 262757A rcmove the pinion head bearing track and shim and drift out the outer bearing track from the differential housing. continucd

151

REAR DIFFERENTIAL - HEAVY DUTY

S T 5 0 8 M

12. Remove the pinion head bearing with service tool

MS 47 and adaptor 18G 47-6.

13. For rcasscmbly purposes, add alignment marks to the crown wheel and differcntial case halves.

WARNING: To avoid personal injury, the differential assembly must be very securely retained while removing the bolts from the crown wheel and case halves, as these bolts are Loctited and may be difficult to remove.

A retaining fixture can be made from angle iron with a tube and two bolts welded to it, as illustrated, so that when the fixturc is clamped in a vice, the differential assembly can be located over the tubc with the fixture bolts between the case webs.

14. Remove the crown wheel.

15. Remove thc screws holding t h e case halves together.

16. Withdraw the upper half of the casing.

17. Withdraw the upper side gear. Note that there may be thrust washers fitted t o the side gears.

ST1202M

18. Dismantle the pinions and crosspin assembly, noting the relevant positions of all components.

19. If required, extract the rollcl- bearings and place them in thcir relative outer tracks.

INSPECTING

30. ~~~~i~~ damage. components for obvious wear or

21. A11 bearings must be press fit, except the flange end pinion bearing, which must be a slide fit on the shaft.

22. The crown wheel and pinion are only supplied as a matched set and must not be interchanged separately.

23. Bevel pinion housing and bearing caps are matched sets and must not be interchanged separately.

24. The differcntial case halves are a matched set and must not be interchanged separately. New screws for securing the case halves are already coated with a dry locking compound and do not require the application of Loctite. If t h e old screws are being reused, t h c threads must bc cleaned and coated with Loctite ‘Studlock’ just prior to assembly. p:>.

%.*.

S T 8 8 9 M

RE A R DIFFERENTIAL - NINETY DUTY 51.

~ 2 , - ~ ;

, >

%.A

NOTE: If thrust washers were removed from the side gears during dismantling, the washers must be lubricated with EP90 oil and refitted during the following procedure.

DO

NOT allow oil holes or bolts that are to be Loctited. to contact any

25. Position the smaller case half with the open side uppermost and fit the side gear into the case.

26. Assemble the crosspins, pinions and thrust washers, lubricate the thrust washers with EP90 oil.

27. Fit the crosspin assembly on to the side gear already contained in the differential case half, ensuring that the gears locate correctly.

28. Fit the other side gear to the crosspin assembly

29. ensuring that all the gears locate correctly.

Fit the two case halves together, maintaining the alignment marking and ensuring correct gear mating.

30. Fit the correct (high grade) screws and tightcn them evenly to a torque of 3,0 to 3,7 kgf m (22 to

27 Ibf ftj (30 to 36 Nm).

31. Check that the serial number marked on thc pinion end face matches that marked on the crown wheel.

32. Ensure that the differential housing flange and crown wheel are thoroughly clean. Align the crown wheel with the diffcrcntial case, fit the bolts and washers and tighten evenly.

33. If removed, press on the differential roller bearings.

34. Place the differential housing complete with crown wheel and bearings i n the pinion housing.

35. Fit the bearing caps and bolts. Do not fully tighten the bolts.

36. Fit the bearing adjusting nuts and adjust to obtain zero end-float.

37. Tighten the bearing cap bolts.

38. Using a dial gauge check the crown wheel for run-out. This should not exceed 0,10 mm

(0.004 in). If excessive run-out is recorded remove the crown wheel and examine crown wheel and mounting flange for burrs, grit, etc. Refit the crown wheel and recheck. Run-out, attributable to a buckled or damaged differential housing flange can be corrected only by renewing t h e differential gear housing.

39. When satisfied that run-out is within t h e specified limits remove the differential housing from the pinion housing.

40. Remove the crown wheel bolts and refit them using

Loctite ‘Studlock’. Evenly tighten the bolts to 5,5 to 6,3 kgf m (40 to 45 Ibf ft).

ST891M

Drive pinion

41. Fit the pinion head bearing track and the original shim to the pinion housing using service tools

R O 262757A and R O 262757-1. I f the original shim was damaged or mislaid use a new shim of at least 1,27 mm (0.050 in) thickness.

42. Fit t h e pinion outer bearing track to the pinion housing with service tool R O 262757A and

R O 262757-2.

NOTE: Instructions 41 and 42 are carried out in one operation as illustrated.

43. Fit the pinion head bearing to the pinion using service tool 18G 47-6. continued

. .. .

.I.

REAR DIFFERENTIAL - DUTY

44. Enter the pinion in its location in the pinion housing. Do not fit the shims for bearing pre-load at this stage.

45. Fit the outer bearing and spacer.

46. Fit t h e driving flange, washer and nut.

51. The nominal setting dimension is represented by the setting gauge block 18G 191-4 which is referenced from the pinion end face to the bottom radius of the differential bearing bore.

Drive pinion adjustment

52. Ensure that the pinion end face is free of raised burrs around the etched markings.

53. Remove the keep disc from t h e magnetised base of dial gauge tool 18G 191.

54. Place the dial gauge and setting block on a flat surface and zero the dial gauge stylus on the setting block.

NOTE: 'The setting block has three setting heights as follows:

39.50 mm Rationalised axle

38.10 mm Pre-Rationalised axle

30.93 mm Salisbury axle

Ensure that the height marked 39.50 mm is used for this differential.

47. Do not fit the oil seal at this stage.

48. Tighten the pinion flange n u t slowly until the force required to rotate the pinion is 23 to 40,5 kgf cm

(20 to 35 Ibf in). This will pre-load the bearings in order to check the pinion height dimension.

NOTE: If using original bearings, which are bedded in, the pre-load figure is 11,5 to 17,25 kgf cm (10 to

15 in Ib).

Drive pinion markings

49. The markings on the end face adjacent to the serial number are of no significance during servicing.

50. The figure marked on the end face opposite to the serial number indicates, in thousandths of an inch, the deviation from nominal required to correctly set the pinion. A pinion marked plus (+) must be set below nominal, a minus (-) pinion must be set above nominal. An unmarked pinion must be sct at nominal.

55. Position the dial gauge centrally o n the pinion end face with the stylus rcgistering on the loweqt point on one differential bearing bore. Note the dial gauge deviation from t h e 7eroed setting. continued g -

T. ,

ST894M

I I

REAR DIFFERENTIAL - HEAVY DUTY

151 I

;::-,:;:

. ..

56. Repeat on t h e other bearing bore. Add together the readings then halve the sum to obtain the mean reading. Note whether the stylus has moved up or down from the zeroed setting. a.Where the stylus has moved down, the amount is equivalent to t h e thickness of shims that must be removed from under the pinion inner track to bring the pinion down to the nominal position. b.Where the stylus has moved up, the amount is equivalent to the additional thickness of shims required position. to bring the pinion up to the nominal

57. Before adjusting the shim thickness, check the pinion face marking and if it has a plus (+) figure, subtract that amount in thousandths of an inch

...

. .

. ..

.. ~ previous item.

58. Alternatively, if the pinion has a minus (-) figure, add the amount t o the shim thickness figure.

,Adjust the shim thickness under the pinion head bearing track as necessary.

59. Recheck the pinion height setting. If the setting is correct, the mean reading on the dial gauge will agree with the figure marked on the pinion end face. For example, with an end face marking of +3, the dial gauge reading should indicate that the pinion is +0.003 ins.

Bearing pre-load adjustment

60. Remove the pinion flange, pinion, outer bearing and spacer.

61. Slide new shims, of the same thickness as the originals (bearing pre-load) into position on the pinion shaft. If the original shim was damaged or mislaid use a new shim of at least 4,06 mm

(0.160 in) thickness.

62. Enter t h e pinion i n its location in the pinion housing and fit t h e outer bearing and spacer.

63. Fit the driving flange, washer and n u t .

64. Do not fit the oil seal at this stage.

65. With t h e pinion flange nut tightened to a torque of

9,6 to 16,5 kgf m (70 to 120 Ibf ft) (95 to 163 Nm) the force required to rotate the pinion shaft should be within 23 to 40,25 kgf cm (20 to 35 lbf ins) when initial inertia has been overcome. Change the bearing pre-load shim as necessary to obtain this requirement. A thicker shim will reduce pre-load; a thinner shim will increase pre-load.

NOTE: If using original bearings, which are bedded in, the pre-load figure is 11,s to 17,s kgf,cm (10 to

15 in Ib).

66. Remove the pinion flange.

67. Fit the oil seal (seal lips towards t h e pinion), using service tool 18G 1382 oil seal replacer.

ST897M

68. Lubricate the seal lips with EP90 oil. Fit the distance piece and flange and secure with washer and nut. Tighten t h c nut to 9,6 to 16,5 kgf m (70 to

120 Ibf ft) (95 to 163 Nm). Fit a new split pin. continucd

ST898M

, 1.

. .

ST120lh

REAR DIFFERENTIAL - NINETY HEAVY DUTY

69. Place the differential housing in the pinion housing.

70. Fit the bearing caps and bolts. Do not fully tighten the bolts.

71. Fit the bearing adjusting nuts.

72 Using service tool R0530105, slackcn the left hand bearing adjustment n u t (as illustrated) to produce end float.

76. Evenly tighten the bearing cap bolts torque

8,3 kgf m (60 Ibf ft) (82 Nm).

77. Recheck crown wheel/pinion backlash.

78. Lubricate the bearings and gears.

STQOOM

73. Tighten thc right hand n u t until crown wheel/ pinion backlash is just removed.

74. Tighten the left hand nut slowly until the crown wheel/pinion backlash is 0.10 to 0117 mm (0.004 to

0.007 in).

75. Fit the locking fingers and roll pins. If nccessary, tighten the adjustment nuts slightly to align the locking finger with a slot.

Pinion bearing pre-load ........................................

Crown wheel run-out ...........................................

Crown wheel/pinion backlash ................................

DATA

23 to 40,25 kgf cm (20 to 35 Ibf in)

0,10 mm (0.004 in)

0,10 to 0,17 m m (0.004 to 0.007 in)

REAR DIFFERENTIAL

TEN

...

..,

..,,A

- ,

OVERHAUL REAR AXLE DIFFERENTIAL

ASSEMBLY (SALISBURY) LAND ROVER ONE TEN

MODELS

Service tools:

47 screw press;

18G 131 C axle spreader or axle compressor GKN 131;

1SG 191 dial gauge, bracket and base;

18G 1122 screw press;

18G 1205 spanner for drive coupling;

S 123 A pinion bearing cup remover;

18G 47 BK pinion bearing cone removerheplacer;

18G 47 BL differential bearing remover;

18G 1122 G pinion bearing cup replacer;

1% 134 DP differential bearing replacer;

18G I91 P setting gauge for pinion height or I8G 191-4 universal setting block;

18C 131 F pegs for axle spreader;

RO 1008 oil seal replacer

DISMANTLE

NOTE: All fixing bolts used on the differential assembly and differential cover have metric threads.

1. Drain off thc differential lubricating oil, and refit

PI ug.

2. Remove the rear axle assembly from the vehicle.

3 . Remove the hub driving mcmbcr fixings.

4. Withdraw the driving membcr and axle shaft sufficiently to disengage the differential.

5 . Repeat instruction 4 for the other axle shaft.

6. Remove the fixings and support strip at the differential cover and withdraw the cover and joint washcr.

7. Note the relationship marking on the bearing caps and axle casing to ensure correct refitting.

8. Remove the fixings and withdraw the differential bearing caps.

ST639M

Using axle spreader 18G 131 C

9. Clean out and examine the spreader tool pegholes provided in the gear casing face; ensure that the holes are free from dirt and burrs and damage.

10. Ensure that the turnbuckle adjuster is free to turn.

11. Fit the axle spreadcr to engage the peg holes.

Spreader 18G 131 C, Adaptor pegs 1% 131 F.

12. Using a spanner, turn t h e adjustcr until all free play between the spreader and casing is takcn up, denoted by the adjuster becoming stiff to t u r n .

13. Check that the side members of the spreader are clear of the casing.

14. Stretch the casing, rotating the adjuster by one flat at a time, until the differential assembly can be levered out. Do not lever against the spreadcr; use suitablc packing under the levers to avoid damage to the c a m g .

CAUTION: To prevent permanent damage to the gear carrier case, it must not be over-stretched.

Each flat on the turnbuckle is numbered to enable a check to be made on the amount turned. The maximum stretch permitted is 0,30 mm (0.012 in), equivalent to three tlats.

15. Ease off the adjuster and remove t h e spreader

ST650M

REAR DIFFERENTIAL - TEN

Using axle compressor GKN 131

16. Place the tool on to t h e differential casing, as illustrated, with t h e weld seam uppermost.

Ensure that the plates rest squarely on the differential machined surface and the end bars butt against the edges of the casing.

17. Tighten the adjusting nuts by hand only, until all slack is taken up.

18. Continue to tighten both nuts alternately with a spanner, one flat at a time, to a maximum of three flats.

19. Carefully lever-out the differential assembly.

21. Note t h e alignment markings on the two differential casings to ensure correct refitting, then remove the fixings.

22. Lift off the upper case.

23. Withdraw the upper differentiai wheei and thrust washer. e

ST597M

Dismantle differential

20. Add alignment marks between the crown whccl and thc differential case for reasscmbly purposes, then removc the fixings and withdraw the crown wheel.

24. Lift out the cross-shaft and pinions.

25. Withdraw thc four dished thrust washers.

26. Withdraw the lower differential wheel and thrust washer. continued

ST652M

I r

...,

”

:>,,

27. Remove the differential bearing cones using remover 18G 47 BL and adaptors 1 and 2 and press 47.

28. Withdraw thc shim washers fitted between the bearing cones and the differential casings.

REAR DIFFERENTIAL -

151 I

34. Withdraw t h e outer bearing cone.

35. Extract the pinion inner bearing cup and shim washers from the casing. Note t h e shim washer thickness. Remover

S

123 A .

36. Extract the pinion outer bearing cup from the casing. Remover

S

123 A .

_ . .

Remove final drive pinion

29. Prevent the coupling flange from rotating and remove the flange locknut and plain washer.

Spanner 18G 1205.

30. Support the drive pinion and remove the coupling flange by tapping with a hide hammer.

31. Withdraw the drive pinion together with the inner bearing cone.

32. Withdraw and discard the collapsable bearing spacer.

33. Withdraw the oil seal, gasket and oil thrower.

37. Remove the inner bearing cone from the pinion.

Remover 18G 47 R K and Press 47. continued

151

REAR DIFFERENTIAL- T EN

INSPECTION

38. Examine all components for obvious wear or damage.

39. The bearing cones must bc a press fit on their locations, except the drive pinion flange and bearing which is a slide fit.

40. The crown wheel and pinion are supplied as a matched pair and must not be interchanged separately.

A new crown wheel and pinion matched pair may be fitted to an original gear carrier casing i f sound.

The original crown wheel and pinion, if sound, may be fitted into a replacement casing.

41. The two parts of the differential unit casing arc matched and must not be replaced separately.

42. Discard and renew all thrust washers.

43. Differential housings with worn thrust washer

- seatings must be replaced as a pair.

44.- face for burrs and damage which could lead to crown wheel run-out when fitted.

ASSEMBLE

Assemble differential unit

45. Fit the differential lower wheel and thrust washer to the differcntial case. Sec illustration following instruction 23.

46. Fit the dished thrust washers.

47. Fit the cross-shaft and pinions.

48. Fit the differential upper wheel and thrust washer.

49. Fit the differcntial upper case lining-up the marks.

50. Secure the assembly with bolts using Loctite

'Studlock' grade CVX on the thrcads and tighten evenly and diametrically to 9 , l to 10,4 kgf m (66 to 75 Ibf f t ) .

51. Fit thc crown wheel to the differcntial casing. Use

Loctite 'Studlock' gradc CVX on the fixing bolt threads and tighten to 13 to 13,5 kgf m (95 to

105 Ibf f t ) .

52. Prcss on t h e differential roller bearing cones less shim washers, using 18G 134 DP, and leave t o one side until required for instruction 96.

53. Fit the bearing cups to the differential.

54. Fit the differential unit and bearings to the gear carrier casing, and rotate unit 10 centralize the bearings. Do not fit the bearing caps.

55. Position a suitablc dial gauge indicator on the casing with t h e stylus registering on the back face of the crown wheel.

56. Rotate the differcntial and chcck the total indicated run-out on the crown wheel back facc.

This must not exceed 0,05 m m (0.002in). If run-out is excessive, check the mating faces for dirt and damage; if ncccssary, select a new radial position for t h e crown wheel. When satisl'actory, continue with the following check.

- .

-, . i

* -

Differential bearing adjustment

57. Insert two levers between the casing and the differential u n i t at one side.

58. Movc the differcntial unit fully to one side of the casing; do not tilt the unit.

59. Rotate the differential unit to scttle the bearings, continuc to lever the differential to the side, then zero the dial gauge indicator.

60. Lever the assembly fully to the other side of thc casing, rotate the unit to settle the bearings, then note t h e total indicator reading.

&T;

. I?:

- ." continued

REAR DIFFERENTIAL

TEN

61. Add 0,127 mm (0.005 in), for bearing pre-load, to the total noted in the preceding instruction. ‘The sum is then equal to the nominal value of shims required for the differential bearings:

Shims are available in the range 0,07 mm

(0.003 in), 0,12 mm (0.005 in), 0,25 mm

(0.010 in) and 0,76 mm (0.030 in). Sclect the total value of shims required.

62. Remove t h e differential unit and bearings and place aside. Do not fit the shim washers until thc subsequent ‘Differential backlash’ checks have been made, instructions 96 to 102.

Fit drive pinion

63. Select shim washers of the same thickness v a h e as those removed from under the pinion inner cup, instruction 35, and place ready for fitting.

64. Position the outcr bearing rcplacer 18G 1122 G

~ detail 2, and the outer bearing cup on the press tool 18G 1122.

65. Locate the assembly into the pinion housing nose.

’.. . .

ST662M

70. Press the inner bearing cone onto thc drive pinion. 18G 47 B K , details 1 and 2 and press 47.

71. Position the pinion and bearing in the casing; omit the collapsablc spacer at this stage.

72. Fit the outer bearing cone onto the pinion.

73. Fit the coupling flange and plain washcr and loosely fit the flange nut.

74. Tighten the coupling flange locknut to remove end-float from the pinion.

75. Rotate the pinion to settle the bearings and slowly tighten the flangc locknut. Use a spring balancc to obtain a torque resistance of 9,25 to 13,8 kgf cm

(8 to 12 Ibf in) to rotate t h e pinion. continued

ST661 M

66. Place the selected shim washcrs on to the inner bearing cup seating.

67. Position t h e inner bearing cup in the casing.

68. Position the inner bcaring replaccr 18G 1122 G detail 1, onto 18G 1122 and secure with the fixing nut.

69. Hold still t h e centre scrcw and turn the butterfly lever to draw in the bearing cups.

70%

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151

REAR DIFFERENTIA L - E TEN

Drive pinion markings

76. Check that the serial number marked on the pinion end face matches that marked on the crown wheel,

77. The markings on the end face adjacent to the serial number are of no significance during servicing.

78. The figure marked on the end face opposite to the serial number indicates, in thousandths of an inch, the deviation from nominal required to correctly set the pinion. A pinion marked plus (+) must be set below nominal, a minus (-) pinion must be set above nominal. An unmarked pinion must be set at nominal.

Drive pinion adjustment

80. Ensure that the pinion end face is free of raised burrs around the etched markings.

81. Remove the keep disc from the magnctized basc of dial gauge tool 18G 191.

82. Place the dial gauge and setting gauge 18G 191 P or 18G 191-4 on a flat surface and zero the dial gauge stylus on to the setting gauge.

83. Position the dial gauge centrally on the pinion end facc with the stylus registering on the lowest point on one differential bearing bore. Note the dial gauge deviation from the zeroed setting.

84. Repeat on the other bearing bore. Add together the readings, then halve the sum to obtain the mean reading. Note whether the stylus has moved up or down from the zeroed setting.

ST649M

79. The nominal setting dimension is represented by the setting gauge block 18G 191 P or 18G 191-4, which is referenced from the pinion end face to the bottom radius of the differential bearing bore.

The latter gauge is illustrated following instruction 85.

ST1380M

---

Example 1

Rcading obtained L.H. sidc

Reading obtained R . H . side

Add

0.006 in

- 0.003 in

0.003 i n

Divide b y 2 =

0.0015 in

0.006 in if??

.r” - 0.003 in

Therefore subtract 0.0015 in from the shim thickness behind the pinion inner bearing track.

Example 2

Reading obtained L.H. side

Reading Chtained R.H. side

Add

0.006 in

- 0.008 in

0.002 in

- 0.002

Divide b y 2 = ____ = - O.UO1 in

0.006 in

O , ( ) f i f j i E continued

..:.

.,.

I -

85a.Where t h e stylus has moved down, the amount is equivalent to the thickness of shims that must be removed from under the pinion inner cup to bring t h e pinion down to the nominal position. b.Where t h e sty!us has moved up, the amount is equivalent to the additional thickness of shims required to bring the pinion up to the nominal position.

Illustration A. Using setting gauge 18G 191 P.

Illustration B. Using universal setting block 18G 191-4

NOTE: The setting block has three setting heights as follows:

39.50 mm Rationalised axle

38.10 mm Pre-Rationalised axle

30.93 mm Salisbury axle

Ensure that the height marked 30.93 mm is used for this differential.

REAR DIFFERENTIAL - TEN

86. Before adjusting the shim thickness, check the pinion face marking and if it has a plus (+) figure, subtract that amount in thousands of inch from the shim thickness figure obtained in the previous instruction. Alternatively if the pinion has a minus

(-) figure, add t h e amount to the shim thickness figure.

87. Adjust the shim thickness under the pinion inner cup as necessary, by the amount determined in instructions 85 and 86.

88. Recheck the pinion height setting instructions 82 to 84. If t h e setting is correct, t h c mean reading on the dial gauge will agree with the figure marked on the pinion end face. For example, with an end face marking of +3, the dial gauge reading should indicate that the pinion is 0.003 in below nominal.

89. When the pinion setting is satisfactory, temporarily remove t h e pinion outer bearing.

ST645M

ST646M

90. Fit a new collapsable bcaring spdcer, flared end outward, to the drive pinion and refit the outer bearing.

91 Fit the pinion oil slinger

92. Fit the oil seal gasket. concinucd

S T 6 4 7 M

ST644M

REAR DIFFERENTIAL -

93. Fit the pinion oil seal, lipped side first, using general purpose grease or, where available, a molybdenum disulphide based grease on the seal lip, using R O 1008 to drift in the seal.

Fit the coupling flange and plain washer and 94. loosely fit a new flange nut. Secure 18G 1205 to the coupling flange, using slave fixings.

95. Alternately tighten the flange nut and check the drive pinion resistance to rotation until the following figures arc achieved, as applicable: a.Assemblies re-using original pinion bearings: 17,3 to 34,5 kgf cm (15 to 30 Ibf in). b.Assemblies with new pinion bearings: 3 4 3 to

46,O kgf cm (30 to 40 Ibf in).

NOTE: Once the bearing spacer has started to collapse the torque resistance build-up is rapid, therefore check frequently, using a spring balance, to ensure the correct figures are not exceeded, otherwise a new collapsable bearing spacer will be

- required.

ST643M

102. Fit the shim value determined in instruction 101, taking the shims from the pack previously determined during ‘Differential bearing adjustment’ checks, instructions 57 to 62

18G 47 BL details I and 2, prcss 4 7 , l S G 134 DP.

103. Fit the remaining shims from instruction 101 to the opposite side o f the differential. 18G 47 BL details 1 and 2, press 47, 18G 134 DP.

104. Fit t h c differential unit with shims and bearings to the axle casing, using t h e axle spreader 1% 131 C with pegs 18G 131 F.

105. Remove the axle spreader.

106. Fit the bearing caps in their correct position, referring to the relationship markings on the caps and on the axle casing.

107. Tighten the bearing caps fixings to 12,9 to

14,5 kgf m (93 to 105 Ibf ft).

108. Mount a dial gauge on the axle casing with the stylus resting o n a crown wheel tooth. continued

Differential backlash checks

96. Pick up the differential unit as left after instruction 52.

97. Fit the differential u n i t and lever the unit away from the drive pinion until t h e opposite bearing cup is seated against the housing. Do not tilt the unit.

98. Install a dial gauge on the casing with its stylus resting on the back face of the crown wheel. Zero the gauge.

99. Lever the differential unit to engage the crown wheel teeth in full mesh with the drive pinion teeth. Dc net ti!t t h e unit.

100. Note the total reading obtained on the dial gauge.

101. From this figure subtract 0,25 mm (0.010 in) to obtain the correct crown wheel backlash w h e n fitted. The result indicates the value of shimming to be fitted between the differential case and the bearing cone at the crown wheel side of the differential.

REAR DIFFERENTIAL -

109. Prevent the drive pinion from rotating and check the crown wheel backlash which must be 0,15 to

0,27 m m (0.006 to 0.011 in). If the backlash is not within the specified limits, repeat the differential backlash checks, instructions 96 to 102 looking for possible errors.

110. Fit the differential cover and new gasket, coating both sides of the gasket with Hylomar PL 32M or an equivalent non-setting sealant.

Torque load for fixings is 2,s to 3,5 kgf m (20 to

25 Ibf ft).

111. Reverse instructions 3 to 5 and coat t h e threads of the hub driving member bolts with Loctite

‘Studlock’ grade CVX and fit and tighten the bolts evenly. Torque: 10,O kgf m (73 Ibf ft).

112. Fit the rear axle assembly to the vehicle.

113. Replenish thc differential lubricating oil, (see

Lubrication chart). After the initial axle run,

- check thc oil level and replenish as necessary to the fillerAevel plug hole.

ST640M

114. Where major running parts have been replaced during servicing, it is a recommended practice to allow t h e axle assembly to ‘run in’ by avoiding, where possible, heavy loads and high speeds during initial running.

Crown wheel backlash .........................................

Differential bearings pre-load ................................

Pinion height setting ............................................

DATA

0,15 to 0,27 m m (0.006 toO.O1l in)

0,127 m m (0.005 in)

Set using gauge 18G 191 P or 18G 191-4

Torque resistance initial setting figures

Torque to turn drive pinion and new pinion bearings ...

Torque to tum drive pinion re-using the original bearings .

34,5 to 46 kgf cm (30 to 40 Ibf in)

17,3 to 3 4 3 kgf cm (15 to 30 Ibf in)

REAR DIFFERENTIAL

FRONT DIFFERENTIAL

OVERHAUL AXLE DIFFERENTIAL ASSEMBLY

Service tools:

18G 1205 flange holder tool;

18G 191 pinion height setting gauge;

18G 191-4 universal setting block;

18G 47-6 pinion head bearing removerheplacer;

LST 106 oil seal replacer; or

RO 262757A extractor for pinion bearing caps;

RO 262757-1 replacer-use with RO 262757A;

RO 262757-2 adaptor tail bearing cap replacer;

KO 530105 spanner-differential flange and carrier bearing nuts;

RO 530106 bracket for dial gauge and indicator;

MS 47 press

DISMANTLE

It is essential that differential components are markcd in their original positions and relative to other components so that, if refittcd, their initial setting is maintained. Note that the bcaring caps must not be interchanged.

1. Remove the differentlal assembly from the axle.

2. Drift out the roll pin sccuring the bearing n u t locking fingers to the bcaring caps. Remove the locking fingers.

3. Slacken the bearing cap bolts and mark the caps for reassembly.

4. Using service tool R O 530105, remove the bearing adjusting nuts.

5. Remove the bearing cap bolts and bearing caps.

6. Lift out of the crown whecl, differential unit and bearings.

ST505M

9. Withdraw the pinion complete with pinion head bearing and outer bearing shims. Withdraw the shims.

10. Remove the pinion flange oil seal, spacer and bearing. Discard the oil seal.

ST506M

11. Using service tool R O 262?57A, remove the pinion head bearing track and shim and drift out thc outer bearing track from t h e differential housing.

7. Remove the split pin securing the pinion flange n u t .

8, R~~~~~ t h e p i n i o n flange n u t using service tool

18G 1205 to restrain the flange.

12. Remove the pinion head bearing with service tool

MS 47 and adaptor 18G 47-6.

,..

. ....

.,.

... .

REAR DIFFERENTIAL -NINETY

FRONT DIFFERENTIAL NINETY AND ONE TEN

ASSEMBLE

Differential gears

21. Fit the differential gears to the differential housing.

22. Fit the differential cross shaft and retaining circlips.

ST508M

13. Remove t h e bolts and washers securing the crown wheel t o the differential flangc. Withdraw the crown whecl.

14. Remove the differential carrier bearings.

15. Remove the circlips securing the differential cross shaft. Extract the cross shaft.

16. Withdraw thc differential gears and pinions.

17. Thoroughly clean all components.

STSIOM

23. Check the gear for freedom of rotation and backlash. Nominal backlash should be present.

Excessive backlash will necessitate renewal o f the gears and/or the differential housing. N o provision is made for backlash adjustment.

24. Check that the serial number marked on the pinion end face matchcs that marked on the crown wheel.

7-5. Ensuring that the differential housing flange and crown wheel are, thoroughly clean fit the crown wheei. Fit t h e cmwn wheel bolts and washcrs and evcnly tighten.

26. Fit the carrier bearings using a suitable press or drift and assemble the tracks to the bearings.

ST509M

INSPECTION

18. Check all bcarings for wear and/or pitting.

19. Check all gears for wear, scuffing, pitting and damaged teeth.

20. NOTE. The crown wheel and pinion are supplied as a matched set, also the pinion housing and bearing caps.

ST511 M

REAR DIFFERENTIAL -

FRONT DIFFERENTIAL -NINETY AND ONE TEN

27.

28.

29.

Place the differential housing complete with crown wheel and bearings in the pinion housing.

Fit the bearing caps and bolts. Do not fully tighten the bolts.

Fit t h e bearing adjusting nuts and adjust to obtain

30. zero end-float.

Tighten the bearing cap bolts.

L I

ST512M

31. Using a dial gauge check thc crown wheel for run-out. This should not exceed 0,10 mm

32. can be corrected only by renewing the differential gear housing.

When satisfied that run-out is within the specified limits remove the differential housing from the

33. pinion housing.

Remove the crown wheel bolts and refit them using

Loctite 'Studlock'. Evcnly tighten the bolts to t h e correct torque.

ST514M

36. Fit the pinion head bearing to thc pinion using service tool 18G 47-6.

4 w

34. Fit the pinion head bearing track and the original shim to the pinion housing using service tools

R O 262757A and R O 262757-1. If the original shim was damaged or mislaid use a new shim of at least 1,27 mm (0.050 in) thickness.

35. Fit the pinion outer bearing track to the pinion housing with service tool KO 262757A and

R O 262757-2.

NOTE: Instructions 34 and 35 are carried out in one operation as illustrated.

37. Enter the pinion into its location in the pinion housing. Do not fit the shims for bearing pre-load at this stage.

38.

39.

Fit the outer bearing and spaccr.

Fit the driving flange, washer and n u t . continued

REAR DIFFERENTIAL

FRONT DIFFERENTIAL - NINETY AND ONE TEN

_,.

..,

.'.:I

...,

. I . .

ST516M

40. Do not fit the oil seal at this stage.

41. Tighten t h e pinion flange n u t slowly until the force required to rotate the pinion is 23 to 40,25 kgf cm

(20 to 35 Ibf in). This will pre-load the bearings in order to check the pinion height dimension.

NOTE: If using original bearings, which are bedded in, the pre-load figure is 11,5 to 17,25 kgf cm (10 to

15 in Ib).

Drive pinion adjustment

45. Ensure that the pinion end face is free of raised burrs around the etched markings.

46. Remove the keep disc from the magnetised base of dial gauge tool 18G 191.

47. Place the dial gauge and setting block on a flat surface and zero the dial gauge stylus on the setting block.

NOTE: The setting block has three setting heights as follows:

39,50 mm Rationalised axle

38,10 mm Pre-Rationalised axle

30,93 mm Salisbury axle

Ensure that the height marked 39,50 mm is used for this differential.

Drive pinion markings

. I - .

. . ,

42. The markings on the end face adjacent to the serial number are of no significance during servicing.

43. The figure marked on t h e end face opposite to t h e seripl number indicates, in thousandths of an inch, the deviation from nominal required to correctly set the pinion. A pinion marked plus (+) must be set below nominal, a minus

(-1 pinion must be set above nominal. An unmarked pinion must be set at nominal.

44. The nominal setting dimension is represented by the setting gauge block 18G 191-4 which is referenced from t h e pinion end face to the bottom radius of the differential bearing bore.

ST518M

48. Position the dial gauge centrally on the pinion end face with the stylus registering on the lowest point on one differential bearing bore. Note the dial gauge deviation from the zeroed setting.

43 continued

. ._

..<

ST517 I I

REAR DIFFERENTIAL -

FRONT DIFFERENTIAL -

49. Repeat on the other bearing bore. Add together the readings then halve the sum to obtain the mean reading. Note whether the stylus has moved up or down from the zeroed setting. a. Where t h e stylus has moved down, the amount is equivalent to the thickness of shims that must be removed from under the pinion inner track to bring the pinion down to the nominal position. b. Where the stylus has moved up, the amount is equivalent to the addition thickness of shims required to bring the pinion up to the nominal position.

50. Before adjusting the shim thickness, check the pinion face marking and if it has a plus (+) figure, subtract that amount in thousandths of an inch from the shim thickness figure obtained in the previous item.

51. Alternatively, if the pinion has a minus (- ) figure, add the amount to the shim thickness figure.

Adjust t h e shim thickness under the pinion head bearing track as necessary.

52. Recheck the pinion height setting. If the setting is correct, the mean reading on the dial gaugc will agree with the figure marked on the pinion end face. For example, with an end face marking of +3, the dial gauge reading should indicate that the pinion is +0.003 in.

58. Tighten the pinion flange nut to the specified torque. The force required to rotate the pinion shaft should be within 23 to 40,25 kgf cm (20 to

35 Ibf i n ) when initial inertia has been overcome.

Change the bearing pre-load shim as necessary to obtain this requirement. A thicker shim will reduce pre-load; a thinner shim will increase prc-load.

NOTE: If using original bearings, which are bedded in, the pre-load figure is 11,5 to 17,25 kgf cm (10 to

15 in Ib).

59. Remove the pinion flange.

Fitting Pinion Oil Seal -latest type FRC 8220

CAUTION A -

FRC 8220 in place of the early type FRC 4586 the latest mudshield FRC SI54 must be fitted in place of the early type 236072.

Also seal replacer ISG 1382 must be used to fit the early type oil seal FRC 4586. This tool must not be used to fit latest seal FRC 8220.

CAUTION B differential, examine the seal to ensure that it is clean, undamaged and that the garter spring is properly located. A small scratch on the seal lips could impair its efficiency.

60. Coat thc outer diameter of the new seal with an all-purpose grease and fit the seal, lip side leading squarely on the pinion nose