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Land Rover Defender 90 110 Workshop 1984 Rover Manual

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    							DIESEL FUEL SYSTEM -TURBO CHARGED ENGINE El 
    ........ ........ a-. COOLING SYSTEM 
    ......:;.... .. ? Type ................................................................. Pressurized spill return  system  with thermostat  control, I. >::.:::: :: ..,. pump and fan assisted 
    Thermostat  opening temperature 
    ............................. 82°C 
    Pressure cap 
    ........................................................ 1,0 kgf cm2 (15 Ibf in2) 
    Water  pump type ................................................. Centrifugal 
    Fan  type 
    ............................................................. 7 blade  with viscous  coupling 
    Radiator 
    .............................. , .... , ........................ 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 
    differential 
    Low 
    3.3198:l 
    Ratios  Ninety  and One  Ten .................................... High 1.4109: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 
    Front  wheel  drive ................................................. 
    Ratio ................................................................. 3.54: 1 
    Overall  ratio (including  final drive) 
    Ninety and 
    One Ten  models .................................... 
    Type-Ninety  models .............................................. Spiral bevel 
    Enclosed  constant velocity joint 
    In high 
    transfer 
    Fifth  (Cruising  gear) 
    4.15:l 
    Fourth 4.991 
    Third  7.53: 1 
    Second 
    1 1.49: 1 
    First 17.90:l 
    Reverse 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 
    .... 
    43  
    						
    							1191 DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE 
    ENGINE TUNING DATA 
    ENGINE 
    Injection  timing ................................................... 13 R.T.D.C. 
    Firing order ........................................................ 1-3-4-2 ... 
    Timing marks: 
    .. Valve timing ....................................................... Slot for peg in 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 mm (0.010  in) 
    Valve timing 
    Inlet opens .......................................................... 16B.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 
    ..................................................... 13 A.T.D.C. 
    Exhaust  peak 
    ...................................................... 109 R.T.D.C. 
    Valve lift 
    Inlet .................................................................. 9,85 mm (0,388 ins) 
    Exhaust 
    ............................................................. 10,26 mm (0.404  ins) 
    Maximum governed speeds 
    Full load ............................................................. 4000 r.p.m. 
    No load  (flight  speed) ............................................ 4400 k 80 r.p.m. 
    Dic-down time ..................................................... 4 seconds 
    Idle 
    speed 
    ........................................................... 670 * 20 r.p.m. 
    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 
    and  fuel  adjustment  screws. 
    Advance  box (two  stage) 
    ........................................ 7 advance with 3 start retard 
    Back  leakage  rate 150
    -100 Atm: 
    Direction 
    of rotation 
    ............................................. Clockwise,  viewed from drive cnd 
    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 mm 
    length .............................................. 457,2 mm (18  ins) 
    HEATER PLUGS 
    iviaiteitype .......................................................... rrobe type, Cnampion CE63 i i v~iis 90 waits iicjiiiiiiai 
    Time  to reach  operating  temperature of 850°C ............ 8 seconds 
    ., n 
    TURBO-CHARGER 
    Makehype .......................................................... Garrett T2 
    Maximum boost pressure ....................................... 48 cm HG (9.3  P.S.I.G.)  measured  at wastegate  actuator 
    T piece 
    44  
    						
    							DIESEL FUEL SYSTEM - TURBO CHARGED ENGINE I 191 
    TORQUE WRENCH SETTINGS 
    TURBO
    -CHARGER FlXINCS Nm Ibf.ft 
    Stud-Turbo  charger to exhaust  manifold 
    22-28 16-2 1 
    Nut-Turbo charger  to exhaust  manifold 
    2 1-26  15-19 
    Adaptor
    -Oil  feed  to cylinder  block 
    22-28 16-21 
    Adaptor
    -Oil  drain  to cylinder  block 
    22-28 16-21 
    Pipc
    -Oil  feed to turbo  charger 
    15-22 11-16 
    Pipe-Oil drain 
    32-48 23-35 
    Stud
    -Outlet  elbow to turbo charger 
    22-28 16-2 1 
    Nut-Outlet elbow to turbo  charger 
    2 1-26  15-19 
    Heat  shield  support  to inlet  manifold 
    22
    -28 16-2 1 
    Stud
    -Exhaust  manifold  to cylinder  head 
    30-40 22-30 
    Nut
    -Exhaust  manifold  to cylinder  head 
    28-36 2 1-26 
    Screw
    -inlet  and exhaust  manifold  to cylinder  head 
    30-40  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. They are SHPD  (Super  High Performance  Diesel) oils that  allow a 
    maximum of 10,000 km (6,000  miles) between  oil and  filter  changes. 
    BP 
    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 if 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. 
    BP Vanellus  C3 Multigradc 15/40 
    CASTROL  Dcusol RX Super  15/40 
    DUCKHAMS Hypergrade  15/50 
    ESSO Essolube XD-3 15/40 
    MOBIL  Delvac Super 15/40 
    PETROFINA  Fina Dilano  HPD 15/40 
    SHELL 
    Rimula X 15/40 
    TEXACO URSA  Super Plus 15/40 
    Use only oils to MIL-L-2104C/D or API  Service  levels CD or SE/CD-ISW/40 SECTION 10 
    MAINTENANCE SCHEDULE 
    The following  additional  maintenance  is required for the  turbo  charged  engine to that  contained in thc main schcdulc 
    for the non-Turbo  Charged  2.5 Litre  Diesel  cngine. 
    Every 
    500 km (250  miles) 
    - Check  engine  oil level 
    At  1,600 
    km (1,000  miles),  10,000 km (6,000 miles) and 20.000 km (12,000  miles) then every  20,000 km (12,000 
    miles) 
    - Check tappets, and adjust if necessq 
    Every  80.000 km (48,000  miles) 
    - Check maximum  turbo-charge boost pressure.  
    						
    							19 
    TURBO-CHARGER 
    DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE 
    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 the turbo- 
    charger. 
    7. Disconnect  from the turbo-charger the lubrication 
    inlet  pipe. 
    8. Disconnect,  at the flexiblc hose,  the lubrication 
    drain  pipe from  the turbo
    -charger. 
     \\  \ \\ \ 
    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. 
    : *-=- 
    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. 
    46  
    						
    							DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE 119 
    ST1863M 
    13. Fit the  exhaust  downpipe  to  the  turbo-charger 
    14. Connect the lubrication  inlet pipe to the  turbo- 
    15. Fit the oil drain  pipe to the  flexible  connection. 
    16. Connect  the  boost control  pipe  to the turbo- 
    17. Fit the  hose connecting  the inlet manifold  to turbo- 
    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. 
    elbow 
    and tighten  the clamp  bolt. 
    charger. 
    charger. 
    charger. 
    CHECKING  TURBO-CHARGER BOOST PRESSURE 
    1. Disconnect, from the  turbo-charger, the 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 the 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 the 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 - 9.7 p.s.i.g.) 
    47  
    						
    							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 two 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. The 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 
    CHARGER.  CIRCUMSTANCES,  DISMANTLE THE 
    TUKBO- 
    VISUAL INSPECTION 
    1. 
    7 -. 
    3. 
    4 
    5. 
    Inspect all connections  within the intake  system. 
    Tighten  loose connections 
    as required. 
    Replace  damaged  air intake  components. 
    Check  the connection  between the compressor  and 
    the  engine  intake manifold. 
    Tighten  loose 
    bolts as required. 
    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. 
    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. 
    48  
    						
    							COOLING SYSTEM 1261 
    I -. ENGINE PROTECTION  DRAIN AND FILL VS ENGINE  COOLING  SYSTEM .. .. ”.! .. 
    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 
    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 
    the onset ofthe 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 
    the 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 to 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. 
    ” parts. ., .. 
    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 the 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 the 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. 
    1  
    						
    							1261 COOLING SYSTEM 
    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 
    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. 
    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 do 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 
    the 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  
    						
    							.-._ ... . (y ; ,:, I :.,. .I, ....... : . . 
    - . ., .. ,. , .. . 
    .: . ’ ’.: ,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. 
    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 of 
    the capacity for topping  up and the expansion  tank. 
    7. Check all hoses and  drain plugs for  security  and fill 
    the system  through the 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 the air cleaner  hose from the 
    carburetter  and remove the  air cleaner. 
    9. Release the 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 the 
    radiator  and separate  the  two  units  noting  that the 
    cowling  is held 
    to the bottom  of the radiator  by two 
    clips. 
    continued 
    3  
    						
    							1261 COOLING SYSTEM 
    FITTING THE RADIATOR 14. 
    12. 
    13. 
    Locate the cowling  into thc clip at the  bottom of 
    the radiator  and secure it at the  top with the  five 
    screws.  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. 
    15, 
    16. 
    17. 
    18. 
    Secure  the top of the radiator with the two  brackets 
    and  bolts. 
    Secure  the cowling 
    to the  engine. 
    Connect  the top,  bottom  and overflow  hoses. 
    Diesel engine 
    Fit the hose to the vacuum  pump and secure it with 
    the  clips 
    on the cowling. 
    Fit the  air cleaner  and connect  the hose to the air 
    intakc manifold. 
    All engines 
    Check  that the radiator  drain plug (where  fitted) is 
    tight  and 
    fill the cooling  system. 
    a- 
    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 
    4  
    						
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