Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							r I 
I a LandRover 
Range Rover Workshop Bulletin 
. .. . . .. d:. ..::::,, , .,.. .i ,-., ....- .*..... .., .I,. ‘ATTENTION SERVICE MANAGER JUNE 1987 
BULLETIN NUMBER SLR 621 EN WBI 
LAND ROVER 
SU CARBURETTERS 
GEMMER POWER ASSISTED STEERING 
Further supplies of this  Bulletin can be obtained, free of  charge, from: 
Land Rover  Merchandising  Service 
P.O. Box 534, Erdington, Birmingham B24 00s 
SERVICE Land Rover  Service  Division  
						

							loll CONTENTS - INTRODUCTION 
Section 
Number CONTENTS 
Page 
14 INTRODUCTION 
1191 FUEL SYSTEM 
- Carburetter - Overhaul 
- Carburetters - Tune and adjust 
3 
8 
I57 I STEERING 
- Cemmer power  assisted  steering  box - Overhaul 13 
INTROD UCTI ON 
This Bulletin  covers the Introduction of the twin SU H.I.F. 44 Carburetters  on the  Land Rovcr 90 and 110 V8 
Engine,  and the Gemmer Power assisted  steering  box prior to it being  included  in the updated 90-110 Workshop 
Manual,  which will be numbered 
as follows 
SLR 621  EN WM - English 
SLR 623 FR WM -French 
SLR 624 GR WM - German 
SLR  625 IT WM 
- Italian 
SLR 
622 DU 
WM - Dutch 
2  
						

							FUEL SYSTEM 1191 
5 CARBURETTER OVERHAUL - S.U. HIF 44 - 
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  washcrs  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  complctc  with piston  and spring. 
5. Remove thc spring  clip from  the top  of the  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 vicc 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 sealing  ring. 
S. Remove  the jet adjusting  lever rctaining 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 needlc valve. 
12.  Unscrew  and remove  the needle  valve and filter. 
13. Unscrew  and rcmove the 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 thc bridge side. 
.I . 
15. Remove  the piston  guide pcg. 
16. Remove  the suction  chamber-to-body sealing  ring. 
17. Unscrew  and remove  the mixture  adjusting  screw 
and  seal.  Use thin  nosed  pliers  to  finally withdraw 
thc screw. 
18. Bend-back the cam  lever  nut lock  tabs and remove 
the  nut  and  lock  washer. 
19.  Removc 
the cam  lever  and spring. 
20. Remove  the end  seal  cover  and seal. 
21.  Remove 
the two  screws  and withdraw  the cold  start 
valve  body and seal  together  with the valve  spindle. 
Also collect  the paper  joint washer. 
22.  Note  the position 
of the  throttle  levers and return 
spring. 
23.  Bend
-back  the lock  washer  tabs and remove  the 
throttle 
lcver nut. 
24.  Removc 
the lock washer,  bush washer  and throttle 
actuating  lever. 
25. Releasc the throttle return spring and remove  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 
buttcrfly from the spindle. 
.. . 
con1 
28.  Withdraw  the throttle  butterfly  spindle from the 
carburetter  body together  with 
thc 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 
clcarance. 
31. Check  the float  needle  and seating  for wear  and the 
float  for punctures  and renew 
if necessary. 
32.  Check  the condition  of all 
rubbcr scals, ‘0’ rings 
and  joint  washers  and renew 
if necessary.  The float 
cover piatc seal must  be renewed. 
33.  Examine  the carburettcr  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 the assembly  horizontally  and 
spin 
the piston.  The piston  should  spin freely in the 
suction  chamber  without any tendency  to stick. 
35. Inspcct the  metering  needle tor wear, scores  and 
distortion.  Check also that 
it has the correct 
designation  number 
- see Engine Tuning Data, 
Section 
05. 
36.  Examine  the bi-metal  jet lcver for cracks. 
37.  Check  all springs  for cracks  and distortion. 
ASSEMBLE 
Fit throttle  butterfly 
38. Fit the  throttle  spindle to the carburetter  body and 
inscrt the throttle  disc into  the spindlc 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 prevcnt turning. 
39.  Fit new  seals  to both  ends 
of thc throttle  spindle 
cnsuring that they  are fitted  the corrcct way round. 
Fit  cold  start  assembly 
40. Fit a new ‘0’ ring to the valve  body and assemble 
thc valve  spindle to the valve  body. 
43 40 
STl873M 
41. Fit a ncw paper  joint washer  to the  valve  noting 
that  the half
-moon  cut-out in the washer  is 
clearance  for the  top  retaining  screw. 
tinued 
3  
						

							1191 FUELSYSTEM 
42. 
43. 
44. 
45. 
46. Fit 
the starter 
assembly  to the carburetter  body and 
secure  with the 
two screws. 
Fit the  end seal  and cover. 
Fit  the  return spring. 
Fit  the  cam  lever  and tension  the  spring. 
Fit a new 
lock  washer  and  secure  with the nut  and 
bcnd the 
tabs  over a  convenient  flat. 
Adjust  the coils 
of the  spring, if necessary,  to 
prevent  coil binding. 
ST?974M 45 
KEY TO S.U. CARBURETTER COMPONENTS 
1. 
2. 
3. 
4. 
S. 
6. 
7. 
8. 
9. 
10. 
11. 
12. 
13. 
14. 
1s. 
16. 
17. 
1s. 
19. 
Piston  damper. 
Spring  clip. 
Suction  chamber. 
Piston. 
Piston spring. 
Suction  chamber  retaining  screws 
- 3 off. 
Needle retaining screw. 
Needle  bias spring. 
Needle guide. 
Needle.  Suction  chamber  sealing ring. 
Throttle  adjusting screw  and seal. 
Piston  key and  retaining screw. 
Mixture adjusting screw  and seal. 
Carburetter  body. 
Throttle  butterfly  and retaining  screws. 
Throttle  spindle. 
Throttle  spindle seals 
- 2 off. 
Float chamber.  20. 
Float chamber  cover and retaining  screws. 
21. Float chamber  cover seal. 
22.  Jet assembly. 
23.  Jet bearing. 
24.  Jet bearing  nut. 
25.  Bi
-metal  jet lever. 
26.  Jet retaining  and adjusting  screw and spring. 
27. Float  needle. 
25. Float needle  seat. 
29. 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 levcr assembly  retaining  nut  and lock 
washer. 
continued 
4  
						

							FUEL SYSTEM 19 
5  
						

							19 
56 
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 convenient  flat. 
I 
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 
55. Fit the  needle valve, spring loaded  pin uppermost. 
56. Fit the float  and secure  with the pivot  pin. 
57. Hold  the  carburettcr  in the  inverted  position SO 
that  the necdle valve  is closed  by the  weight of the 
float  only.  Check  using a straight 
edgc that  the 
point  on 
the float, arrowcd on  the  illustration,  is 
1.0 to 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. 
Aftcr adjustmcnt, check that  the  float pivots freely 
about  the spindle. 
seat. 
I/ I 57 F‘ I I 
I ST1876M 
6 contin tied  
						

							FUEL SYSTEM 
:-.sa 59. Assemble the jet to the  bi-metal  jet lever  and 
ensure  that the jet head  moves  freely in the 
cut
-out. 
60. Fit  the  jet and  bi-metal  jet lever to the  carburetter 
and  secure  with the spring  loaded  jet retaining 
screw. 
^L,. ,%’ 
61. Fit  the  mixture  adjusting  screw. 
L 
19 
. 
62. Adjust the mixture  screw until the jet is flush  with 
the  carburetter  bridge, then turn the screw  a 
further  three and one  half  turns  clockwise. 
63. Using a new sealing  ring, fit the  float  chamber 
cover,  noting that it can  only  be fitted  one way. 
Secure  with the four  screws  and spring  washers  and 
evenly  tighten. 
Fit piston and suction chamber 
64. Fit the  needle,  spring and guide assembly  to the 
piston  ensuring  that the etched  arrow 
hcad on thc 
needle locating  guide is aligned between the piston 
transfer  holes, as illustrated. 
65. Secure  and ensure  that when the screw is tightened 
the  guide 
is flush  with thc piston  and that  the screw 
locates 
in the  guide slot. 
I I ST1879M 
66. Fit  the  piston  key to the carburetter  body using ;I 
new screw.  Tighten the scrcw and splay the end. 
67. Fit  a new  suction  chamber  sealing ring to the 
groove in thc carburetter  body. 
68. To prevent the piston  spring  being ‘wound-up’ 
during  assembly,  temporarily 
fit the piston and 
suction chamber  less the spring  to the body, and 
pencil  mark the relationship 
of the  chamber  to the 
body.  Kcmove  the suction  chamber  and 
fit the 
spring  to 
the piston.  Hold the suction  chamber 
above  the 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 
screws,  tightening 
cvcnly and check  that the pislon 
moves  freely. 
69. Hold the piston at the top of its stroke  and fit the 
spring  clip. 
70. Fit the piston dampcr. 
71. Using a new  joint  washer,  fit the air intake adaptor 
and  secure  with the two  nuts  and spring  washcrs. 
72. Fit the carburetters to the inlet  manifold  ensuring 
that 
thc joint  washers,  dcflcctor  and insulator  are 
fitted 
in the sequence  illustrated.  The insulator 
must  be fitted  with 
thc arrow head uppermost  and 
pointing  inwards towards  the manifold.  Secure 
with  the four  nuts 
and spring  washers  and tighten 
eveniy to the correct  torque. 
A. Joint washer. 
B. Deflector-teeth  pointing  inwards. 
C. Joint washer. 
D. Insulator. 
E. Joint  washer. 
continued 
7  
						

							1191 FUELSYSTEM 
MODEL  CARBURETTER  S.U. SPEC EXHAUST CO EXHAUST  IDLE SPEED 
PART No. No. (NEW ENGINE) (After 3000 km) R.P.M. 
TUNE  AND ADJUST - SU HIF 44 CARBURETTERS 
Special  tools: 
Carburetter  balancer 
605330 or B89 
Non-dispersive infra-red exhaust gas analyser. 
FAST IDLE 
SPEED  R.P.M. 
A/IB I C D E 
ALL HICOMP V8 ENGINES 
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 
thc 
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 
F 2 X 2 0 0 6 ETC7121- ETC7  123 
ST 1880M independent  and accurate  tachometer. 
Idling  adjustments  should be carried  out on 
a fully 
thermostat  has opened.  This should  be followed  by 
ag 
run of one minute  duration  at an  engine  speed ofi,; 
approximately 2,500 revhin before  further 
adjustments  or checks  are carried  out. This  cycle  may 
be  repeated 
as often as required.  It is important  that 
the above cycle is adhered to, othcrwise overheating 
may  result  and settings  may be 
incorrcct. 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 ensurc that the 
throttle  linkage 
bctween the pedal  and carburettcrs is 
free  and has no 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. 
73. Connect the linkages and toP-uP the warmed up engine, that is, at ]east 5 minutes after the dampers with a 
hollow piston rod. 
Oil to the top Of le 
74. Tune and adjust  the carburettcrs. 
TAMPER 
- PROOFING 
To  comply  with 
E.C.E. regulations  the idle spced and r;p, mixture  adjusting  screws must be tamper - proofedg: ::: 
following  any adjustments. A red blanking  plug; Part - 
number - JZX 1258 must be fitted  into thc mixture 
screw 
resess and a red  cap;  Part  number JZX 1197 
fitted  over the idle  adjustment  screw (throttle 
adjustment 
scrcw). 
73 
ALL HICOMP V8 ENGINES 
continued 
F 2 X 2 0 0 6 ETC7121- ETC7  123 
ALL  UCOMP 
V8 ENGINES FZX2005 ETC7 124 ETC7 I25 ALL UCOMP V8 ENGINES FZX2005 ETC7 124 ETC7 I25 
600 - 700 
1100 f50 NEW  ENGINE 
700 
- 800 
600 - 700 
NEW  ENGINE 
700 
- 800 RUN-IN  ENGINE^ I 
8  
						

							FUEL SYSTEM 
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. 
19 
CARBURETTER  BALANCE 
Using  balancer 
605330 
1. Disconnect  the  interconnecting link betwccn the 
two  carburetters. 
Fit the balancer  to  the 
carburetter  intakes and ensure  that there  are 
no air 
leaks, 
if necessary,  zero the gauge with the 
adjustment  screw. 
2. Start the engine,  and if necessary  allow it to reach 
normal  operating  temperature.  If 
the needle moves 
to  the  right,  decrease  the 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 idlc 
screw.  Reverse  the procedure 
if the pointer  moves 
to 
the left.  Reconnect  the carburetter  inter- 
connecting link. 
Using balancer I389 
3. Disconnect  the inter-connecting  throttle link 
4. Back-off the idle adjusting  screw on each 
5. Turn each  throttle  adjusting  screw so that it 
equal amounts  to  achieve an approximate  idle 
speed 
of 700 to 800 rev/min. 
6. Press  the balancer  firmly over the carburcttcr 
intake. Press or withdraw  the control on the side  of 
the  balancer 
to adjust  the  meter  needle  reading  to 
approximately  half 
scalc, and note the reading. 
betwccn the two carburetters. 
carburcttter, 
clear of the throttle  lever. 
touches !hp !hrott!e !ever, ther. tgrn the SCI-C’iVS by 
continued 
9  
						

							L 
19 FUEL SYSTEM 
7. Without  altering the position  of the  balancer 
control,  place the balancer  on the  second 
carburetter  intake  and adjust  the idle  screw  as 
necessary 
to achieve  the same  reading. 
8. Alternatively,  adjust and check  the balance  of both 
carburetters 
until an  idle  speed  of 700  to 
800 
rcv/min is.obtained. 
9. Reconnect  the  throttle  inter-connecting link, and 
again  check the  idle speed  and balance. 
Mixture setting 
10. Ensure  that  the cngine is still  at  normal  operating 
temperature. 
11. Mark  the rclationship of the  suction  chamber to the 
carburetter  body,  remove the retaining screws  and 
lift off thc suction chamber  complete  with pistons. 
12. 
To achieve  a datum  setting for the  mixture  screw, 
turn 
it anti-clockwise  until  the jet is level  with the 
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. Rcfit the suction  chamber  and piston,  evenly 
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 
rcading 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, continuc the 
setting procedure  until a stable  CO reading  of 0.5 
to 2.5% at  an  idle  speed of 700-800 rev/min is 
obtained. 
ST1915M 
idle speed and linkage adjustment 
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. . -/ 
ST18 8 3M 
10 
continued