Land Rover 90 110 Workshop Rover Manual
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REAR DIFFERENTIAL - NINETY FRONT DIFFERENTIAL -NINETY AND ONE TEN .. _,. . .... . .., :: ..., ..,./.,i; . .. ..:I ST516M ST517 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. 40. Do not fit the oil seal at this stage. 41. Tighten the pinion flange nut 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). . .I. . .. Drive pinion markings 42. The markings on the end face adjacent to the serial number are of no significance during servicing. 43. The figure marked on the end face opposite to the 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 44. 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. seripl number indicates, in thousandths of an inch, 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. . . .I-. .., nominal. ,I .. 43 I I continued ;. . ._ .. . . . ..< % .. 19
REAR DIFFERENTIAL - NINETY FRONT DIFFERENTIAL - NINETY AND ONE TEN 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 the 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 the 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 in) 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 - When fitting the latest type oil seal 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 - Before fitting the new seal to the 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 housing and drive the seal into position flush with the end face of the Bearing pre-load adjustment 53. Remove the pinion flange, pinion, outer bearing and spacer. 54. 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 nim (0.160 in) thickness. 55. Enter the pinion in its location in the pinion housing and fit the outer bearing and spacer. 56. Fit the driving flange, washer and nut. 57. Do not fit the oil seal at this stage. 61. housing using seal replacing tool LST 106 RR968M Lightly lubricate the seal lips with EP90 oil. Fit the distancc piecc and flange and secure with washer and nut. Tighten the nut to the specified torque and fit a new split pin. ST1405M 20
REAR DIFFERENTIAL - NINETY FRONT DIFFERENTIAL - NINETY AND ONE TEN ?;::;:$ ,:-:. 62. Place the differential housing in the pinion 63. Fit the bearing caps and bolts. Do not fully tighten 64. Fit the bearing adjusting nuts. housing. the bolts. ?I .a. “Wi’ ,’ ..;::,.::# ”.?N 51 ST522M T I, ’ 65 Using service tool 530105, slacken the lcft hand bearing adjustment nut (as illustrated) to produce end float. 66. Tighten the right hand nut until crown wheel/ pinion backlash is just removcd. 66 ST523M .. ...... :., ...... ,.. .... ..... DATA 67. Tighten the left hand nut slowly until it contacts the bearing. Continue turning the left -hand nut until a backlash of 0,10 to 0,17 mm (0.004 to 0.007 ins) is achieved. Do not slacken the right-hand nut at any time, otherwise thc bearing preload will be affected. 68. Fit the locking fingers and roll pins. If necessary, tighten the adjustment nuts slightly to align the locking finger with a slot. 69. Evenly tighten the bearing cap bolts to the 70. Rcchcck crown whecl/pinion backlash. 71. Lubricate the bearings and gears. specified torque. Pinion bearing pre -load ........................................ 23 to 40,25 kgf cm (20 to 35 Ibf in) Crown wheel/pinion backlash ................................ 0,10 to 0,17 mm (0.004 to 0.007 in) Crown wheel run -out ........................................... 0,10 mm (0.004 in) 5.. > :..: .: .. ..., ‘2, , . ’ :... .. 21
PRINTED IN ENGLAND BY COVENTRY PRINTERS (2/87 372101 .-. ::. ... .. .
Section Number 70 57 STEERING BRAKING SYSTEM CONTENTS Page -Overhaul manual steering box -Overhaul steering column -Overhaul power steering box -Bleeding power steering system -Test power steering system -Adjust power steering box - Overhaul power steering pump - V8 engine vehicles - early models - Overhaul Adwest lightweight power steering box - Bleeding Adwest lightweight power steering box -Test Adwest lightweight power steering box - Adjust Adwest lightweight power steering box - Overhaul Gemmer power steering box -Power steering - fault diagnosis - Overhaul drop arm joint -Adjusting track rod and drag link joints Adwest early models I I 164 I SUSPENSION 1 3 8 16 16 18 18 20 30 30 31 32 43 44 46 - Overhaul front hub assembly -Overhaul stub axle, axle shaft constant velocity joint and swivel assembly 1 3 - Description ~, -Overhaul front brake calipers - Overhaul rear brakes - ‘90’ models - Overhaul rear brakes - ‘1 10’ models - Overhaul transmission brake - Bleeding brakes - Overhaul master cylinder -Fault diagnosis n I76 I CHASSIS AND BODY 1 2 6 7 8 10 11 14 - Chassis dimensions - ‘90’ models - Chassis dimensions - ‘110’ models - Kemoving door trim - ‘90’ ana ’iiW - Rearside doors and window mechanisms - ‘90’ and ‘1 10’ - Front doors and window mechanisms - ‘90’ and ‘1 10’ - 1 3 6 7 12 .. 1
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 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 thc section and book numbers. The cover of each book details thc 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 removcd, the water pump end of the engine is referred to as the front. To reduce repetition, operations covered in this manual do not include referencc to testing the vehicle aftcr rcpair. It is essential that work is inspected and tested aftcr completion and if necessary a road test of the vehicle is carried out 6: T particularly where safety relatcd items are concerned. .t DIMENSIONS The dimensions quoted are to design engineering specification. Altcrnative unit equivalents, shown in brackets ColJowing the dimensions, have bccn converted from the original specification. During the period of running-in from new, certain adjustments may vary from the specification figurcs given in this Manual. These adjustments will be re -set by the Distributor or Dealer at the After Sales Service, and thereafter should bc 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. Attcntion 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 impaircd 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 &++. sctting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified, ; must bc fitted. If the efficicncy 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 invalidatcd by the fitting of other than Land Rover parts. All 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 arc 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, fucl, 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 This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of your local Fire Officer. safely. It also outlines the other areas of risk which must not be ignored. g-; = I1
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 ... , ~ ;;;,:ii.,;:: .... , .C I._..1 .. , .. . ... _ potentially very dangerous. Always have a fire extinguisher containing FOAM CO2 GAS, or 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 petrol/gasoline is being handled, drained or stored, or 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. 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 petrol/gasoline 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 PETROL/GASOLINE HAS BEEN EXTRACTED OR DRAINED FROM A FUEL TANK THE PRECAUTIONS GOVERNING NAKED LIGHTS AND IGNITION SOURCES SHOULD BE MAINTAINED. FUEL TANK REMOVAL On vchiclcs where the fuel line is secured to the fuel tank outlet by a spring steel clip, it is recommended that such clips are reieased 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 PETROWGASOLINE 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 sedimcnt 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 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 or 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 Manufacturers policy of constant product improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, ncither thc 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 thereof. COPYRIGHT @ Land Rover Limited 1984 , , . . .. .I ., . . . . ... . . .. : 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. , .. ,. ... 111
. Special Service The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safcly. 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. Countries where there is no distributor may order direct from V. L. Churchill Limited, PO Box 3 Daventry, Northants, England NNll4NF. 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 Merchandising Service, P.O. Box 534, Erdington, Birmingham B24 OQS.
STEERING GEMMER MANUAL STEERING BOX OVERHAUL Special tool: RO 1016 Dismantle 1. Remove the steering box from the vehicle, and 2. Remove the adjuster locknut. 3. Remove the four bolts securing the top cover. 4. Unscrew the top cover from the adjuster. 5. Lift out the sector shaft. 6. Remove the four bolts securing the worm shaft retaining plate and remove the plate complete with shims and joint washer. remove the drop arm. 7. Remove the taper bearing and track. 8. Withdraw the worm shaft and collect the opposite taper bearing. .9. Drift out the worm shaft oil seal. 10. Drift out the shaft-end bearing track and collect the shim. Note since this shim or one of the same value must be refitted, as a precaution against loss, check the thickness with a micrometer and note the reading. 11. Prise out the sector shaft oil seal. 12. Drift out the sector shaft needle roller bearings. Inspection 13. Clean and degrease all parts and examine for wear 14. Renew the bearings (if worn), oil seals and joint 15. If the bearing in the top cover is worn renew the Assembling Cleanliness, during the following instructions, is essential. 16. Press or drift in the worm, shaft-end, bcaring track ensuring that the same shim or one of the same value is fitted behind the track. It is essential that the track is fitted squarely and pressed fully home. 17. Lubricate and fit the bearing to the shaft and insert the shaft into the box. 18. Lubricate and fit the opposite bearing and track to the worm. 19. Fit the cover plate, joint washer and original shims. Secure with the four bolts and evenly tighten to 25 to 30 Nm (18 to 22 Ibs ft). 20. Check the worm shaft bearing pre -load by attaching special tool R01016 or a similar alternative 63,5 mm (2.5 in) diameter, to the worm shaft. Wrap string round the tool and attach a spring balance to one end and with a steady pull note the rolling resistance which should be 2.26 to 2.72 Kg (5 to 6 Ibs force). Adjust by adding or subtracting shims. When the correct figure is achieved, remove the bolts, coat the threads with sealant and fit and evenly tighten to within the above torque figures. - and damage. washers and any other unsatisfactory parts. complete cover with bearing. 57 ST 887M 21. With the lip side leading fit the oil seal to the shaft -end of the box. NOTE: When performing instructions 22, 23 and 26 pressure must only be applied to the hardened square end of the bearings. 22. Press in the sector shaft top bearing to a depth of 83 mm (3.150 in) from the top machined face of the steering box. 23. Press in the sector shaft lower bearing 1,OO mm (0.040 in) below the chamfer. 24. Check that no end-play exists in the sector shaft adjuster. To reduce end-play unstake the threaded cup and turn clockwise until all play is removed and restake. 25. Fit the sector shaft so that the roller is in the centre of the worm in the straight ahead position. 26. Fit the bearing to the sector shaft top cover. 27. Screw the top cover onto the adjuster and secure with the four bolts and evenly tighten to 25 to 30 Nm (18 to 22 Ibs ft). 28. Loosely fit the adjuster locknut. 29. Keeping the sector shaft in the straight ahead position fit the drop arm and turn the adjuster clockwise until pre -load is applied to the shaft. The amount of pre-load should be such that when the shaft is turned half a turn to the left then half a turn to the right, the backlash must only just be perceptible. When satisfactory tighten the adjuster locknut. 30. Fit the sector shaft oil seal. 31. Remove the oil filter plug and pour in approximately 0,43 litres (0.75 pints) of the appropriate recommended oil to a minimum level of 25 mm (1.0 in) below the top of the filler hole. Refit the plug and tighten to 20 Nm (14.75 Ibs ft). 1
157 I STEERING ST885M KEY TO MANUAL STEERING BOX 17 1. Adjuster lock nut. 2. Top cover retaining bolts. 3. Topcover. 4. Top cover joint washer. 5. Sector shaft. 6. Worm shaft retaining plate and bolts. 7. Worm shaft shim(s). 8. Worm shaft joint washer. 9. Worm shaft. 10. Worm shaft taper bearing. 11. Worm shaft oil seal. 12. Worm shaft bearing track shim. 13. Sector shaft oil seal. 14. Sector shaft needle roller bearings. 15. Worm shaft grommet. 16. Sector shaft adjuster. 17. Sector shaft threaded cup. 18. Oil filler plug and washer. 2