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Land Rover 90 110 Workshop Rover Manual

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    							SLRSZ1EìWh.I  
    						
    							TABLE OF CONTENTS 
    SECTION 
    Introduction 
    mI ........................................................................\
    .............................. 
    ........................................................................\
    ........... 
    El 
    General  Specification  Data 
    .......................... Engine Tuning  Data.. .I!. ............................................................. 
    ........................................................................\
    ............. Torque  Wrench  Settings.. mb 
    ........................................................................\
    .......... mI General  Fitting Instructions 
    ..................................................... 
    ........................................................................\
    ............................. El 1 
    Recommended  Lubricants, Fluids and Capacities.. 
    Maintenance 
    El 
    El 
    El 
    Engine ........................................................................\
    ..................................... 
    ,~ Cooling  System ........................................................................\
    .......................... 
    ..................................................................... Fuel System (including  Fuel Injection) 
    ... . ..I 
    Clutch.. ........................................................................\
    .................................... OJ 
    ........................................................................\
    . w 
    El 
    w 
    Manual  Gearbox  and Transfer  Box 
    Propeller  Shafts.. 
    Rear Axle and Final  Drive 
    ........................................................................\
    ........................ 
    ........................................................................\
    ............ 
    ........................................................................\
    ..................................  Steering.. 
    Suspension 
    ........................................................................\
    ................................ 
    Brakes ........................................................................\
    ..................................... 
    Electrical ........................................................................\
    .................................. 
    BOOK 
    2 
    5  
    						
    							BOOK ONE CONTENTS 
    05 
    Page 
    ENGINE TUNING DATA 
    Section 
    Number 
    ri 
    -Repairs and replacement  parts 
    - Poisonous substances 
    -Fuel handling precautions 
    -Fuel tank draining  and repair J 
    .. - 
    - Service  tools 5 
    - Location of vehicle identification  numbers 6 
    06 TORQUE WRENCH SETINGS 
    El GENERAL SPECIFICATION  DATA 
    - V8 engine data 
    -2.25 litre petrol  engine  data 
    -2.25 litre petrol  engine data 
    - 2.25 litre dicscl cnginc data 
    -2.50 litre dicsel  engine  data 
    - General  data - all models 
    -Tyre  pressures 
    - Replacemcnt bulbs  and units 
    - Vchiclc wcights 
    1 
    3 
    5 
    7 
    9 
    11 
    19 
    19 
    20 
    - V8 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 
    7 
    :I.. i , .. . ... ,.. .E. , 
    1  
    						
    							Book One Contents (cont’d) 
    07 
    Section 
    GENERAL FITTING INSTRUCTIONS 
    -Precautions  against damage 
    -Safety precautions 
    -Preparation  and dismantling 
    -Inspection of components 
    -Ball  and roller  bearings 
    - Oil seals 
    -Joints  and joint  faces 
    - Flexible  hydraulic  pipes and hoses 
    - Metric  bolt identification 
    - Metric  nut identification 
    - Hydraulic  fittings 
    - Keys and keyways 
    -Tab washers,  split pins,  nuts and locking  wire 
    - Screw threads 
    - Unified  thread identification 
    1091 RECOMMENDED  LUBRICANTS, FLUIDS AND CAPACITIES 
    1 
    1 
    1 
    2 
    2 
    2 
    3 
    3 
    3 
    4 
    4 
    5 
    5: 
    5 
    6 
    - 
    - Recommendcd lubricants 
    - Anti-freeze  proportions 
    -Corrosion  inhibitor 
    -Capacities 
    -Maintenance  Schedules 
    -Maintenance - lubrication 
    -Maintenance - general maintenance  and adjustments 
    2  
    						
    							01 
    fi;y :i: INTRODUCTION ... ,:.; :.? , ... ..:I. .!I, I . ._ ...,., , . ... 
    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 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 of replacement  parts and 
    accessories: 
    Safety  features  embodied  in the  vehicle  may be impaired 
    if other  than Land  Rover  parts are fitted.  In certain 
    territories,  legislation prohibits the  fitting of parts  not to the  vehicle  manufacturers  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 
    readily  be distributed  throughout  a workshop  by air  current,  consequently,  even a small  spillage  of 
    petrol/gasoline is 
    potentially  very dangerous. 
    .. . .... . becomes  a readily  ignitable  mixture. The vapour  is heavier  than air and  will always  fall to the  lowest  level. It can 
    3  
    						
    							lo1 I 
    Always have a fire  extinguisher  containing FOAM CO? GAS, or POWDER  close at hand  when  handling  or draining 0 
    fuel,  or 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,  or 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 ONE  SHOULD  BE PERMITTED  TO REPAIR  COMPONENTS  ASSOCIATED WITH PETROL/ 
    GASOLINE  WITHOUT FIRST HAVING  HAD 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  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  OR DRAINED  FROM A FUEL TANK  THE 
    PRECAUTIONS  GOVERNING NAKED LIGHTS 
    AND IGNITION  SOURCES SHOULD BE MAINTAINED. 
    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. 
    fi-- k. 
    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 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 
    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  or 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 Manufacturers 
    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. 
    4  
    						
    							- 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 NNll 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. 
    5  
    						
    							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 - front  axle 
    F Maximum  road weight - rear axle 
    I 
    I 
    I 
    fAND 
    &IR 
    TOO1 
    ST037 I 
    ENGINE  SERIAL NUMBER - VS ENGINE 
    The V8 engine serial number  is stamped on a cast  pad 
    on the  cylinder  block between  numbers 3 and 5 
    cylinders. 
    6 
    ST 
    ENGINE  SERIAL NUMBER - 4 CYLINDER 
    ENGINES 
    The 4 cylinder  engine number  is stamped  on a 
    machined  surface at the  front  left
    -hand side of the 
    On  later  engines  the number  is stamped  above the rear 
    side  cover,  as the  second  illustration  shows. 6” engine adjacent  to the  exhaust  manifold  front flange. -. -  
    						
    							LOCATION OF VEHICLE IDENTIFICATION  AND UNIT  NUMBERS 
    ST663M 
    01 
    FRONT  AXLE 
    Stamped  on top of the  left-hand  axle tube. 
    REAR  AXLE 
    Stamped  on rear of left-hand  axle tube. 
    MAIN  GEARBOX  LT77 - 4 CYLINDER  VEHICLES 
    Stamped on a pad  on the  right-hand  side of the  gearbox 
    immediately  below the 
    oil filler level plug. 
    U 
    ST665M 
    TRANSFER  GEARBOX LT230R - 4 CYLINDER 
    VEHICLES 
    Stamped  on the  casing  on the  left-hand  side of the 
    gearbox  below the mainshaft  rear bearing  housing 
    adjacent  to the  bottom  cover. 
    Y ST664M 
    TRANSFER  GEARBOX LT230T - 4 CYLINDER 
    AND  V8 VEHICLES  FROM SERIAL  NUMBER 
    SUFFIX 
    ‘B’ ONWARD 
    MAIN  GEARBOX 
    LT85 FIVE SPEED - V8 
    VEHICLES 
    Stamped  on the  right-hand  side of the front  bearing 
    plate. 
    STl546M 
    7  
    						
    							GENERAL SPECIFICATION DATA 
    ENGINE 
    Type ................................................................. 
    Number of cylinders ............................................. 
    Bore ................................................................. 
    Stroke ............................................................... 
    Capacity ............................................................ 
    Valve operation.. ................................................. 
    Maximum  power- B.H.P ..................................... 
    Maximum power - KW.. ...................................... 
    Maximum  torque ................................................. 
    04 
    V8 
    Eight, two banks of four 
    88,90 mm (3.500  in) 
    71,12 mm (2.800 in) 
    3528 
    cc (215 in) 
    Overhead by push-rod ._ 
    13 } at 4000rpm 84.6 
    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 mm (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 mm (0.004 - 0.008 in) 
    .. ................................. 
    Main  bearings 
    Number  and type .............................................. 5, Vandervell  shells 
    0,010 
    - 0,048 mm (0.0004 - 0.0019  in) 
    0,254 
    mm, 0,508 mm (0.010  in, 0.020  in) 
    Material 
    ......................................................... Lead-indium 
    Diametrical  clearance 
    ........................................ 
    Undersizes ...................................................... 
    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 ....................................... 0,015 - 0,055 mm (0.0006 - 0.0022 in) 
    End
    -float  on crankpin ....................................... 0,15 - 0,36 mm (0.006 - 0.014 in) 
    Undersizes 
    ...................................................... 
    Vandervell VP lead-indium 
    0,254 
    mm, 0,508 mm (0.010 in, 0.020  in) 
    Gudgeon pins 
    Length ........................................................... 72,67 - 72,79 mm (2.861 - 2.866 in) 
    Fit
    -in  connecting  rod ......................................... 
    Clearance in piston ............................................ 0,002 - 0,007 mm (0.0001 - 0.0003 in) 
    Diameter 
    ........................................................ 22,215 - 22,22 mm (0.8746 - 0.8749 in) 
    Press fit 
    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) 
    1  
    						
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