Range Rover Classic (1987) Workshop Manual - smithies.co.nz

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Range Rover Classic (1987) Workshop Manual - smithies.co.nz

CONTENTS. .. . . .,.’ ‘,,SectionNumberPage:a..,.INTRODUCTION- Accessories and conversions- Abbreviations and symbols- Fuel handling precautions- Hot fuel handling precautions- Fuel tank transfer and repair- Glossary of terms- Location of identification numbers- Poisonous substances- Repairs and replacement parts- Special service tools- Specification- Steam cleaning- Used engine oil precautions- Wheels and tyres/04 GENERAL SPECIFICATION DATA- Air conditioning- Brakes- Cooling system- Electrical- Engine- Fuel system- Shift speed specification - 1987-88 Model year- Steering- Suspension- Transmission (LT230 and ZF) ratios- Tyre pressures- Vehicle dimensions- Vehicle weights and payload- Wheels and Tyres- Wiper motors35222661133338738124563121111881989 Model Year- Electrical- Engine 3.9 V8.- Shift speed specification - 1989 model year onwards- Transmission (Borg Warner and ZF) ratios13131514ENGINE TUNINGDATA- Engine tuning data - 3.5 V81989 Model Year- Engine tuning data - 3.9 V8 2REVISED: SEPT. 90


CONTENTS’ (continued)SectionNumberPageGENERAL FI-ITINGREMINDERS_- Ball and roller bearings- Dismantling- Flexible hydraulic pipes and hoses- Inspection - general- joints and joint faces- Keys and keyways- Metric bolt identification- Metric nut identification- Oil seals- Precautions against damage- Preparation- Safety precautionsScrew threads- Tab washers, cotter pins, nuts and locking wire- Unified thread identification324246553111666RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES- Anti-freeze proportions- Capacities- Fuel requirements- Lubrication- Recommended lubricantsi1989 Model Year- Capacity (Borg Warner transfer gearbox)- Fuel requirements- Recommended lubricants (Borg Warner transfer gearbox)331REVISED: SEPT. 90


CONTENTS(continued) c.- .SectionNumberPage10 MAINTENANCEI‘....- Air conditioning- Battery- Brakes- Charcoal canister- Converter housing wading plug- Cooling system- Distributor- Drive belt adjustment- Dynamometer Testing- Emission maintenance reminder - reset - 1988 model year onwards- Filters- General maintenance and adjustments- Ignition- jacking- Jump starting- Lubrication- PCV breather filter- PCV intake filter- Plenum chamber ventilation passageway- Required Emission maintenance-49 States- Requrred Emission maintenance-California- Required maintenance-49 States-California - first 1,000 mile service- Road springs- Steering and suspension- Steering ball joints- Towing- Transporting the vehicle by trailer- Vehicle Hoist (Four post)- Vehicle Hoist (Two post)- Washer bottle202025162420192172915181969101716172112423237877181989 Model Year- Borg Warner transfer gearbox - Top up oil- Renew oil- Charcoal canister - remove and refit- Dynamometer testing - Borg Warner transfer gearbox- Towing - Borg Warner transfer gearbox- Parkbrake - adjust- Emission maintenance reminder31313232323c29.1990 Model Year- Dynamometer testing rolling roads11991 Model Year- Fuel filter1REVISED: SEPT. 90


CONTENTS(continued).: ‘,SectionNumberrl 99 SERVICE TOOLS- Automatic gearbox- Engine- Front and rear axle and final drive- General and basic tools- Power steering-steering- Transfer gearboxPage..’.: I,REVISED: SEPT. 90‘, ,’ ‘,‘.‘.,‘.‘.‘.‘.


l-l 01 INTRGOUCTION‘..(:.: .I:,.,,.: .’:,.‘.FUEL HANDLING PRECAUTIONSThe following information provides basic precautions which must be observed if fuel 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 bemade of your local Fire Marshal or Fire Department.Fuel vapor is highly flammable and in confined spaces is also very explosive and toxic.When fuel evaporates it produces 150 times its own volume in vapor, which when diluted with air becomes areadily ignitable mixture. The vapor is heavier than air and will always fall to the lowest level. It can readily bedistributed throughout a workshop by air current, consequently, even a small spillage of fuel is verydangerous.Always have a fire extinguisher containing FOAM CO, GAS, or POWDER close at hand when handling fuel,or when dismantling fuel systems and in areas where fuel containers are stored.WARNING: It is imperative that the battery is not disconnected during fuel system repairs as arcing atthe battery terminal could ignite fuel vapor in the atmosphere. Always disconnect the vehicle batteryBEFORE carrying out work on a fuel system. Whenever fuel is being handled, transferred or stored, orwhen fuel systems are being dismantled all forms of ignition must be extinguished or removed, anyhead-lamps used must be flameproof and kept clear of spillage.NO ONE SHOULD BE PERMIlTED TO REPAIR COMPONENTS ASSOCIATED WITH FUEL WITHOUT FIRSTHAVING HAD FUEL SYSTEM TRAINING.HOT FUEL HANDLING PRECAUTIONS.;..:‘.i:,,xWARNING: Before commencing any operation requiring fuel to be drained from the fuel tank, thefollowing procedure must be adhered to:1. Allow sufficient time for the fuel to cool, thus avoiding contact with hot fuels.2. Vent the system by removing the fuel filler cap in a well ventilated area. Refit the filler cap until thecommencement of fuel drainage.FUEL TRANSFERWARNING: FUEL MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILE IT IS STANDINGOVER A PIT.1The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approvedtransfer tank must be used according to the transfer tank manufacturer’s instructions and local regulations,including attention to grounding of tanks.FUEL TANK REMOVALA FUEL VAPOR warning label must be attached to the fuel tank upon removal from the vehicle.FUEL TANK REPAIRUnder no circumstances should a repair to any tank be attempted.‘.:“,:.’:: ;_, :.,.:.2 I REVISED: SEPT. 90


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l-iii-l INTRODUCTION:.WHEELS AND TYRESWARNING: DO NOT replace the road wheels with any type other than genuine Range Rover wheelswhich are designed for multi-purpose on and off road use and have very important relationships withthe proper operation of the suspension system and vehicle handling. Replacement tyres must be of themake and sizes recommended for the vehicle, and all tyres must be the same make, ply rating andtread pattern.STEAM CLEANINGTo prevent consequential rusting, any steam cleaning within the engine bay MUST be followed by carefulre-waxing of the metallic components affected. Particular attention must be given to the steering column,engine water pipes, hose clips and ignition coil clamp.SPECIFICATIONThe specification details and instructions set out in this Manual apply only to Range Rover vehiclesmanufactured specifically for the U.S.A. and Canada.The Manufacturers reserve the right to vary their specifications with or without notice, and at such times andin such manner as they think fit. Major as well as minor changes may be involved in accordance with theManufacturer’s policy of constant product improvement.While every effort is made to ensure the accuracy of the particulars contained in this Manual, neither theManufacturer or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for anyinaccuracy or the consequences thereof.COPYRIGHTe Land Rover (UK) Ltd 1987All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted inany form, electronic, mechanical, photocopying, recording or other means without prior written permissionof Land Rover (UK) LtdSPECIAL SERVICE TOOLSThe use of approved special service tools is important. They are essential if service operations are to becarried out efficiently, and safely..J14 .REVISED: SEPT. 90


o;g 1987-91LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS Iii 1FEDERAL VEHICLE IDENTIFICATION NUMBERThe Federal Vehicle Identification Number isstamped on a plate which is riveted to the upperleft hand A - post adjacent to the instrumentbinnacle and is visible through the front screen ofthe vehicle.- 1990 model year (interim condition)additional label contains the Vehicleidentification Number in both bar code and digitalform.ABCAnl D-E\DATEGAWR FRGAWRREAMFD BY LAM ROVER UK LTD EMLAW5997 LBS2511 LBSWITH20W10 TYRES7JXlS RuS@2(1 Ps( Cou)3672 LBS WlTH2OSRl6 TYRES7JXl6 RIMS@41 PSI COLDTHS VEHICLE CONFCfMS TO ALL APPLbCASLEUS FEDERAL MOTOR VEHICLE SAFETY STANOARDSIN EFFECT ON TME DATE OFMANUFACTURE SHOWN ABOVETYPE MWLTI-PURPOSEPASSENOERVECUCLERR2679EVEHICLE IDENTIFICATION NUMBER- 1989 model year onwards(VIN)I.,,,‘.’An adhesive label containing the Federal VehicleIdentification Number, date of manufacture andgross axle weight ratings is fixed to the lock face ofthe front left hand door. The information includeswheel and tyre sizes and tyre pressures at grossaxle weight ratings.- 1989 model year - 1990 model yearA/ MD BY LAND ROVER LM LTD ENGLANDo*rr1B F-“W 5897 LB8GAWR FR- 2636 LBSWIT” 206RR16TYRESC7JX 10 RyJS@ 21)PSdCOLDD-/.MWR REA3672 LBS WITH 2056316 TYRES7JYIS RIM@41 PSI COLDTHS VEHICLE COhFMMS TO ALL APPLICABLEUS FEDERAL MOTOR VEHCLE SAFETY STANOARDSIN EFFECT ON THE DATE OFMAMJFACTURE SHOWN ABOVETYPE MULTI-PURPOSE PASSE))(IER VEHICLEThe Vehicle Identification Number bar code isincorporated in the VIN label.MFD BY LANDROVER UK LTDIENGlANDF 2535LBS WITH 205R16 TYRES-7JX16 RIMS@ 28 PSI COLD3572LBS WITH 205R16 TYRESUS FEDERAL MOTOR VEHICLE SAFETY STANDARDSIN EFFECT ON THE DATE OFRR2679EKEY TO VEHICLE IDENTIFICATION LABELA. Month and year of manufactureB. Gross vehicle weight ratingC. Gross axle weight rating for front axleD. Gross axle weight rating for rear axleE. Vehicle identification number (minimum ofseventeen digits)F. Vehicle identification number - bar codeETYPE MULT I PURPOSE PASSENGER VEHIC LERR271 5EYREVISED: SEPT. 90 7 ‘.:..


LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS1987-91 s;“o”v’;r;I1991 model year2535LBS (115OKg)WIlli 205R16 TVRES7JX16 RIMS 1 28 PSI (193Kpa) COLD2572LBS (162OKS)WITH 205R16 TVRES7JX16 RIMS 3 41 PSI (282K~a) COLDFEDERAL YOTDR VEHICLE SAFETY STANDARDSIN EFFECT ON TliE DATE OFMANUFACTURE SHOWN ABOVE\TYPE MULTI.PURPOSE PASSENGER VEHICLERR2944E2JREVISED: SEPT. 90


,-.R”d;‘;r; 1987-91LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS..VEHICLE IDENTIFICATION NUMBERThe Federal Vehicle Identification Number consists of similar information to the European number and ismade up of a minimum of 17 digits. These numbers are used, to identify manufacturer, model range,specification, body type, engine, transmission/steering, model year, plant and build sequence number andserve to identify the vehicle.The following example briefly shows the coding process:European codevML 4 D AMFed!r al co!te ‘4I I Is AL IiI I IEurope UKRangeRoverNorthAmericanSpec.1I4 DoorStationWagon1I i ii i %3.5 Lithe Fuel Auto: Left Check 1987 Solihull Last six digitsInjection Hand Digit Model identify BuildSteering Year SequenceNumber1988 MODEL YEAREuropean code5 AL t. H VI IFederal codeI II I IEurope UKRangeRoverNorthAmericanSpec.M1I4 DoorStationWagonL 4 E A l - l - - - i1i i i i +-I--I3.5 Litre Fuel Auto. Left Check 1988 Solihull Last six digitsInjection Hand DiRit Model -ibntify BuildSteering - Year:. 1989 MODEL YEAREuropean code5RLlftY aqc 3623 21SALL H V hihl 4 F AI IFederal code4 AL ’)I IEurope UKRange North 4 DborRover American StationSpec. Wagon2Ii ii T 13.9 Litre Fuel Auto. Left Check 1989 S@ihull Last six digitsInjecllon Hand Digit Modelidentify BuildSteering Year SequenceNumber,.: ‘:.a.‘. ‘_. . . ..,REVISED: SEPT. 90 9 ,’:


LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS1987-91 po;;;1990 MODEL YEAREuropean code. .15 AL L HIi--jFederal codeVMhl 4 c Al---T-4Europe UKIHRangeRoverNorthAmericanSpec.14 DoorStationWagon2ii i’ 4I T3.9 Litre Fuel Auto. Left Check 1990 Solihull Last six digitsInjection Hand Digit Model identify BuildSteering Year SequenceNumber1991 MODEL YEAREuropean codes AL L H V1’4Federal codeI I5 AL iI I IEurope UK RangeRoverNorthAmericanSpec.M1I4 DoorStationWagonM 4 H A I i2ii i +-I--I i3.9 Litre Fuel Auto. Left Check 1991 Solihull Last six digitsInjection Hand Digit Model identify BuildSteering Year SequenceNumber /REVISED: SEPT. 90 ,;1’. :


AUTOMATIC GEARBOX ZF4HP22The serial number is stamped on a plate riveted tothe bottom left hand side of the gearbox casing.TRANSFER GEARBOX LT230The serial number is stamped on the left hand sideof the gearbox casing below the mainshaft rearbearing housing adjacent to the bottom cover.,; ’i!AC_.-FRONT AND REAR AXLEThe axle serial numbers are stamped on the top ofthe left hand axle tubes.ENGINE SERIAL NUMBER - 3.5 AND 3.9 V8ENGINEThe WI engine serial number and enginecompression ratio is stamped on a cast pad on thecylinder block, between numbers 3 and 5 cylinders.TRANSFER GEARBOX-BORG WARNER-1989 MODEL YEARThe gearbox serial number is stamped on a platewhich is attached to the gearbox casing and islocated between the filler/level and drain plugadjacent to the rear output housing.NOTE: 3.9 Litre Models can be identified by thesuffix 38D.: “”-..‘.._.REVISED: SEPT. 90 11.’,..


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KA’vbt1987ROVERGENERAL SPECIFICATION DATA-ENGINEType ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...V8Number of cylinders ......................................................... Eight, two banks of fourBore ................................................................................ 88.90mm (3.500 in)Stroke ............................................................................... 71.14mm (2.800 in)Capacity.. .......................................................................... 3528 cc (215 in’)Valve operation ................................................................ Overhead by push-rodMaximum power-bhp-8.13:1 ............................................ 150 at 4750 rev/min (SAEJ1349)CrankshaftMain journal diameter ......................................................Minimum regrind diameter ...............................................Crankpin journal diameter ................................................Minimum regrind diameter ...............................................Crankshaft end thrust/ (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 bearing0.10-0.20 mm (0.004-0.008 in)Main bearingsNumber and type .............................................................Material ............................................................................Diametrical clearance ........................................................Undersize bearing shells ...................................................5, Vandetvell shellsLead-indium0.010-0.048 mm (0.0004-0.0019 in)0.254 mm, 0.508 mm (0.010 in, 0.020 in)....Connecting rodsType .................................................................................Length between centres ...................................................Horizontally split big-end, plain small-end143.81-143.71 mm (5.662-5.658 in)Big-end bearingsType and material .............................................................Diametrical clearance .......................................................End-float crankpin............................................................Undersize bearing shells ...................................................Vandervell VP lead-indium0.015-0.055 mm (0.0006-0.022 in)0.15-0.36mm (0.006-0.014 in)0.254 mm, 0.508 mm (0.010 in, 0.020 in)Piston pinsLength ..............................................................................Diameter.. .........................................................................Fit-in connecting rod ........................................................Clearance in piston ...........................................................72.67-72.79 mm (2.861-2.866 in)22.215-22.220 mm (0.8746-0.8748 in)Press fit0.002-0.007 mm (0.0001-0.0003 in)PistonsClearance in bore, measured at bottom of skirtat right angles to piston pin .............................................0.018-0.033 mm (0.0007-0.0013 in).-i.:.,:.:.F..>..........: .,; ......i~.LPiston ringsNumber of compressions rings ........................................Number of oil control rings. .............................................No. 1 compression ring ....................................................No. 2 compression ring ....................................................Width of compression rings .............................................Compression ring gap ......................................................Oil control ring type .........................................................Oil control ring width .......................................................Oil control ring gap ..........................................................21Chrome parallel facedStepped to ‘L’shaped and marked ‘T’ or ‘TOP’1.56-1.59 mm (0.0614-0.0626 in)0.44-0.57 mm (0.017-0.022 in)Perfect circle, type 98-64.811 mm (0.1894 in) maximum0.38-1.40 mm (0.015-0.055 in)ContinuedREVISED: DEC. 87i


PO;;; 1987GENERAL SPECIFICATION DATA.;.,:.:.: ....,..!I . ...Fuel temperature sensorMake and type ..................................... ............................Lucas 6lT: AhCoolant temperature sensorMake and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lucas 3iTBypass Airvalve (Stepper motor)Make and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lucas 2ACM:_..,Throttle potentiometerMake and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lambda sensorLucas 215SA.,, Make and type ,.,.............................................................. Lucas 3LSCOOLING SYSTEMType .............,........................,.....................................Pressurized system with cross-flow radiator andremote header tank, thermostat control, pump andfan assistedType of pump. ............................................................... . CentrifugalThermostat ....................................... ................................88°C (190°F)TRANSMISSIONTransfer gearbox-LT23tlType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Two speed reduction on main gearbox output.Front and rear drive permanently engaged via alockable differential.Transfer gearbox ratios; High ................................................................................. 1.222:1.... Low .................................................................................. 3.32O:lAutomatic gearboxModel ....................................... ....................................... .Type ..................................... ..................................... .......ZF4HP22Four speed and reverse epicyclic with fluid torqueconverter and lock up.4th ......................................... ......................................... .. 0.728:13rd ................................... ................................... ..............l.OOO:l2nd .................................... .................................... ........... 1.480:11st ......................................... ......................................... ..2.48O:lIIReverse . . . . . . . . . . . . . . . . . . . . . . 2.086:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overall ratio (final drive): High transfer Low transfer. 4th.........................................................................................................3.15:1 8.55:13rd.........................................................................................................4.32:1 11.75:12nd........................................................................................................6.40:1 17.38:11st.........................................................................................................10.72:1 29.13:1Reverse ................................................................................................................. 9.021 2-1.5O:lContinuedREVISED: DEC. 87 3.


GENERAL SPECIFICATION DATA1987-88 PO;;;SHIFT SPEED SPECIFICATIONAutomatic ZF4HP22 GearboxOPERATIONSELECTORPOSITIONMPHVEHICLE SPEEDAPPROX.KPHENGINE SPEEDAPPROX. (RPM)KICKDOWNKD4-3KD3-2KD2-1KD3-4KDZ-3KDI-2D3(D)2(D,3)DD(3)D(3,2)78-95 125-15356-61 90-9827-34 43-55N/AN/A59-64 95103 4750-520034-39 55-63 4600-5250‘.FULL THROlTLE::f=r4-3FT3-2Fr3-4FTZ-3FTl-2D3(D)DD(3)D(3,2)60-66 97-10639-45 63-7273-79 117-127 3980-433054-59 87-95 4350-480029-34 47-55 3950-4650ZERO THROlTLEzT4-3 D 19-25 31-40?iT3-2 D(3) 12-15 19-24zT2-1 D(3,2) 6-7 IO-11PART THROl-t’LEPT4-3PT3-2PT2-1DD(3)DCW46-53 74-8529-36 47-5810-12 16-19LIGHT THROlTLELT3-4 D 26-30 42-48 1430-1650LT2-3 D(3) 18-22 29-35 1420-1820LT’I-2 D(3,Z) 9-10 14-16 1180-12201987 Model yearTORQUE CONVERTERLock Up (IN) 40-43 64-69 1480.1620Unlock (OUT) 38-41 61-66 1430-15601988 Model yearLock Up (IN) SO-53 80-85 1875-2000Unlock (OUT) 48-51 77-82 1825-1930NOTE: The speeds given tn the above chart are approximate and only intended asshift changes should take place within these tolerance parameters.a guided Maxlmurr4 . REVISED: DEC. 87


SUSPENSIONType . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coil springs controlled by telescopic dampers frontand rearTransverse location of axle by Panhard rod, and foreand aft location by two radius armsFore and aft movement inhibited by two tubulartrailing links.Lateral location of axle by a centrally positioned ‘Albracket bolted at the apex to a ball joint mounting.A levelling unit is positioned between the ball jointand upper cross member.ROAD SPRING DATASpecification Part No. Colour Code Rating Free length No of CoilsA 572315 Blue Stripe 2375.1 kg/m 391.16 mm 7.18(133 lb/in) (15.4 in)‘... ”. ..JB NRC4306 Blue 8; White 2375.1 kg/m 417.57 mm 7.55Stripe (133 lb/in) (16.44 in)C NRC8113 Pink & Purple 3182.1 kg/m 418.36 mm 8.75Stripe (178.2 lb/in) (16.47 in)D NTC3285 Green & Pink 3182.1 kg/m 435.2 mm 10.21Stripe (178.2 lb/in) (17.134 in)Standard SuspensionSpecificationRightSideleftSideLHD FrontABLHD RearCDShock absorbers (dampers)Type .................._..............................................................Bore diameter ...................................................................Telescopic, double-acting35.47mm (1.375 in)non-adjustablf?. .\\;6 REVISED: JULY 88‘.‘.


‘.’.’yn;;,: 1987 GENERAL SPECIFICATION DATA I04 1BRAKESFront service brake.(.’Type .................................................................................Operation .........................................................................Disc diameter ...................................................................Total pad area ...................................................................Total swept area ...............................................................Pad material ......................................................................Pad wear indicator ............................................................Dutboard discs with four piston calipersHydraulic, servo assisted self-adjusting298.17mm (11.75 in)98.lcm’ (15.2 in’) per brake816 cm2 (126.48 in’) per brakeDON 230Inboard pad right hand caliper: :’.: .‘, ,,.,‘. ,’‘.‘. .,,.‘..’ ,...-


.WHEELS AND TYRESType and size ...................................................................Tyre size ...........................................................................Alloy 7.001 X 16205R16 (tubeless). Note: Vehicles must be fittedwith ‘S’ rated tyresAIR CONDITIONINGSystem ..............................................................................Compressor ......................................................................- 1988 introduction ..........................................................A.R.A.Sanden SD510Sanden SD 709WIPER MOTORS.Tailgate wiper motorMake/type .........................................................................Running current, wet screen at 20°C ambient .................Wiper speed, wet screen at 20°C ambient ......................IMOS (non-serviceable)1.0 to 2.8 amps37 to 43 cycles per minuteWindscreen wiper motorMake/type .........................................................................Running current (Link disconnected) ................................Rotary link speed ..............................................................Lucas 28W 2-speed1.5 amps at 39 to 45 rev/min (normal speed)60 to 73 rev/min (high speed)ELECTRICAL.ISystem ..............................................................................BatteryMakeltype .........................................................................12 volt, negative groundLand Rover Parts and Equipment/Chloridemaintenance free 14-plate-380/120/90. . ,,AlternatorI..,,‘,’Manufacturer ................................................................... LucasType ................................................................................. 133/80Polarity ..,.......................................................................... Negative groundBrush lengthNew .r.. ........................................................................ 20 mm (0.78 in)Worn, minimum free protrusionfrom brush box ........................................................... IO mm (0.39 in)Brush spring pressure flush with brush box face .............. 136 to 279 g (5 to 10 oz)Rectifier pack output rectification ..................................... 6 diodes (3 positive side and 3 ground side)Field winding supply rectification ..................................... 3 diodesStator windings ................................................................. 3 phase-delta connectedField winding rotor poles ................................................. 12Maximum speed ......................................................... 16,000 rev/minWinding resistance at 20°C ........................................ 2.6 ohms4Control ............................................................................. Field voltage sensed regulationRegulator-type .................................................................. 15 TRvoltage.. ...................................................................... 13.6 to 14.4 voltsNominal outputCondition ................................................................... HotAlternator speed ......................................................... 6000 rev/minControl voltage .......................................................... 14 voltAmp ............................................................................ 80 amp‘, ‘. ,,,, .,‘.,j‘.,.;‘::. ...I .,8 REVISED: MARCH 90;.


”GENERAL SPECIFICATION DATA 1041Coil‘Y,, :,.,:. .:,’ ;‘._. .’ Make/type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas 32C51988 Model Year:, .’ .;,. ..“’ ,:‘. _’ ‘..i,:.Make/type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch 0221 122 392DistributorMake/type .........................................................................Lucas 35 DLM8Firing angles ..................................................................... O”-45”-90” (every 45”) + loApplication .......................................................................12V Negative groundPick-up air gap adjustment(Pick-up limblreluctor tooth) ............................................0.20 mm to 0.35 mm (0.008 in to 0.014 in)Pick-up winding resistance ...............................................2k to Sk ohmsFusesType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Autofuse (Blade type)Blow ratings to suit individual circuitsHornsMake/type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Klamix (Mixo) TR99Ignition moduleMake/type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . Lucas 9EM amplifier module, distributor mountedSpark plugsMake/type .........................................................................Gap...................................................................................Champion RN1 2YC0.85 to 0.95 mm (0.033 to 0.038 in)Starter motorMake/type ......................................................................... Lucas M78R pre-engagedMinimum brush length ............................................... 3.5 mm (0.138)Minimum commutater diameter ................................. 28.8 mm (1.13 in)Continued. . ‘CJ‘....-;.’REVISED: JULY 88 9‘.;:;:


GENERAL SPECIFICATION DATA1987 KANbtRO)/ERREPLACEMENT BULb4TYPE. . :,,ieadlamps4uxiliary driving lampsSidelampsrail lampsieverse lampsStoplampsXrection indicator lampsqear side marker lampsUumber plate lampsInstrument panel lamps and warning lampsIgnition warning lamp (Instrument panel)Interior roof lampsClock illuminationCigar lighter illuminationDoor edge/puddle lampsAuxiliary switch panelillumination (green)Heated rear screen warning lamp (amber)Hazard warning lampAutomatic graphics illuminationHeater/air conditioning graphics illuminationDifferential lock warning lampColumn switch illumination) l2V 60155W (Halogen) sealed beam1 l2V 55W H3 (Halogen)) 12v SW bayonet)Exterior 12v 5l21W bayonetjlights 12v 2lW bayonet) 12v 21w bayonet) 12v 21w bayonet) 12v 4w bayonet) 12v 5w capless) 12v 1.2w bulb/holder unit) 12v 2w capless) 12v low ‘Festoon’) 12v 2w bayonet) 12v 1.2w capless) 12v SW capless)InteriorNights l2V 1.2w capless) 12v 1.2w capless) l2V 1.2w capless) 24v 5w capless) 12v 1.2w capless) l2V 2w bayonet) l2V 1.2w caplessCAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage tvehicle wiring and switches._’,-. . .:: .._;::10 REVISED: JULY 88


RANGLGENERAL SPECIFICATION DATA “*’ ROVER.‘)TYRE PRESSURES2. :‘. .,..’_:Pressures:Check with tyres coldNormal on and off-road use.All speeds and loadsOff-road ‘emergency’ salt use maximiumspeed of 40 kph (25 mph):‘.:.:Front Rear Front RearbarsIbfh’kgflcm’1.91 2.6 1.1 1.628 38 16 232.0 2.7 1.1 1.6These pressures may be increased for high speed motoring, Any such increase in pressures may be up to anabsolute maximum pressure of 2.8 bars (41 psi) 2.9 kgflcm’.Normal operating pressures should be restored as soon as reasonable road conditions or hard ground isreached.After any usage off the road, tyres and wheels should be inspected for damage particularly if high cruisingspeeds are subsequently to be used..,i-Towing: When the vehicle is used forare not applicable.towing, the reduced rear tyre pressures for extra ride comfortWARNING: Tubeless wheels and tyres are fitted to this vehicle and under no circumstances must aninner tube be fitted.TYRE PRESSURES - 1989 model yearRear axle tyre pressures must be increased to 2.8 bars (41 p.s.i.) 2.9 Kgf/cm’ for either of the followingoperating conditions:1. Sustained high speed driving.2. When rear axle loads exceed 3410 Ibs (1550 kgs) e.g. with five passengers plus 220 lb (100 kgs)payload.1 2 REVISED: DEC. 88


R”d;;; 1987-88ENGINE TUNING DATA; .>:..\.,ENGINE TUNING DATAType .................................................................................Firing order .....................................................................Cylinder NumbersLeft bank.. ...................................................................Right bank ..................................................................No 1 Cylinder location ...................................................Timing marks ..................................................................Spark plugsMake/type .........................................................................Gap ...................................................................................CoilMake/type .........................................................................Compression ratio ..........................................................Fuel injection system .....................................................3.5 Litre V8l-8-4-3-6-5-7-21-3-s-72-4-6-8Pulley end of left bankOn crankshaft vibration damperChampion RN1 2YC0.84-0.96mm (0.033-0.038 in)Lucas 32C5 or Bosch O-221-122-3928.13:-lLucas Hot-wire air flow sensor systemelectronically controlledValve TimingOpens ..............................................................................Closes ..............................................................................Duration ...........................................................................Valve peak ........................................................................Idle speed ......................................................................Ignition Timing at ...........................................................Inlet24” BTDC52” ABDC256”104” ATDC665 to 735 rev/min800 revlmin maxExhaust62” BBDC14” ATDC256”114” BTDC_..Ignition TimingDynamic ........................................................................... 6” B.T.D.C. + 1”DistributorMake/type ......................................................................... Lucas 35DLM8 electronicRotation ............................................................................ ClockwiseAir gap .............................................................................. 0.20-0.35mm (0.008-0.014 in)Despatch number ............................................................. 42620Centrifugal AdvanceDecelerating check-vacuum hose disconnectedDistributor rpm decelerating speeds2300 ................................................................................. Distributor advance 8’ to 11”1600 ................................................................................. 8’ 54’ to 11”600 ................................................................................... 1” Id6 to 3” 18’No centrifugal advance below .......................................... 150 rev/minFuelRegular unleaded ..............................................................CLC or AKI octane rating 87 minimumRON octane rating 91 minimum1988 Model YearFuelPremium unleaded ........................................................... CLC or AKI octane rating 90 minimumRON octane rating 9!i minimumREVISED: SEPT 90 1::.


ENGINE TUNING DATA1.. ”'.'. : ,:,:'. ..,..‘,Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Litre VBFiring order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-8-4-3-6-5-7-2. . .Cylinder NumbersLeft bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3-5-7 .Right bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-6-8No 1 Cylinder location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulley end of left bankTiming marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On . . . crankshaft vibration damperSpark plugsMake/type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RNl2YCGap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.84-0.96mm (0.033-0.038 in)CoilMake/type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch o-221-122-392Compression ratio . . . . . . . . . .._.............................................. 8.13:1Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas . . Hot-wire air flow sensor systemelectronically controlledValve Timing Inlet ExhaustOpens .............................................................................. 32” BTDC 70” BBDCCloses .............................................................................. 73” ABDC 35” ATDCDuration ....... .................................................................... 285" 285"Valve peak ........................................................................ 104” ATDC 114” BTDCIdle speed ....................................................................... 665 to 735 rev/minBase idle speed ...................................... ......................... See setting procedure - 525 + 25 rev/min.Ignition Timing at ...........................................................800 rev/min maxIgnition TimingDynamic ........................................................................... 6” B.T.D.C. + 1”. . .DistributorMake/type ......................................................................... Lucas 35DLM8 electronicRotation ............................................................................ ClockwiseAir gap .............................................................................. 0.20-0.35mm (0.008-0.014 in)Despatch number ............................................................. 42648Centrifugal AdvanceDecelerating check-vacuum hose disconnectedDistributor rpm decelerating speeds2300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor advance 8" to 11”II1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8" 54' to 11”600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I" 18' to 3' 18’FuelPremium unleaded (PUG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLC or AKI octane rating 90 minimumRON octane rating 95 minimum2 REVISED: SEPT SO


PO;;; 1987-91TORQUE VALUESTORQUEVALUESLubricants/sealants have been specified in certain applications for assembly purposes.* These bolts must have threads coated with Loctite 572 prior to assembly. For this purpose it isnecessary to use an approved dispenser to apply the sealant/lubricant to the first three threads of thebolts.** These bolts must have threads coated in lubricant EXP16A (Marston Lubricants) prior to assembly.• * • These bolts must have threads coated in sealant Loctite 270 prior to assembly.It is essential that all bolts are securely tightened and it is imperative that the correct torques values areadhered to.COOLING SYSTEM NmOil cooler pipes. ............................................................................................ 26-34Radiator filler plug (plastic) .......................................................................... 5-6ft lb19-25in lb45-54/.EMISSION CONTROLLamda sensor ................................................................................................. 20ENGINEAdaptor plate to crankshaft ..........................................................................Alternator mounting bracket to cylinder head ...........................................Alternator to mounting bracket ................................................. . .................Alternator to adjusting link.. .........................................................................Chainwheel to camshaft ...............................................................................Connecting rod bolt ......................................................................................1577 - 90 57 - 663s - 43 26 - 3222 - 28 16 - 2122 - 28 16 - 2154 - 61 40 - 4547 - 54 35 - 40/:...*.-. .Cylinder head:Outer row .............................................................................................Centre row ...........................................................................................Inner row ..............................................................................................Damper to crankshaft ...................................................................................Distributor clamp nut ....................................................................................Drive plate to converter ................................................................................Engine mountings to engine and chassis ...................................................Engine mounting rubbers to bracketsExhaust manifold to cylinder heads. ...........................................................Fan to viscous unit ........................................................................................Flexible drive plate to crankshaft adaptor plate ........................................Intake 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 plug .......................................................................................Oil sump drain plug ......................................................................................Oil sump to cylinder block ..........................................................................Oil sump rear to cylinder block ...................................................................Plenum chamber to ram housing ................................................................Ram housing to intake manifold .................................................................Rocker cover to cylinder head .....................................................................Rocker shaft bracket to cylinder head ........................................................Spark plug.. .....................................................................................................Starter motor attachment .............................................................................Thermostat housing to intake manifold .....................................................Timing cover to cylinder block ....................................................................Viscous unit to water pump hub .................................................................Water pump pulley to water pump hub .....................................................Water pump timing cover to cylinder block ..............................................Water jacket to plenum chamber ................................................................54 - 61 40 - 45 *88 - 9s 65 - 70 •88 - 95 65 - 70 *257 - 285 190 - 21019 - 22 14 - 1635 - 42 25-30 • *’52 3817 -22 13 1619 - 22 14 - 1626 - 32 19 - 2435 - 46 26-34 • **34 - 41 25 - 3035 - 43 26 - 3268 - 75 SO-55 **88 - 95 65-70 **14 - 20 10 - 1511 - 14 8 - 1024 - 30 18- 2240 - 47 30 - 3540 - 47 30 - 357 - 11 5-817 - 20 13 - 1522 - 28 16 - 2120 - 27 15 - 207 - IO 5- 7434 - 40 25 - 3019 . 22 14 - 1641 - 47 30 - 3524 - 30 18 - 2224 . 30 18. 22 ’40 - 50 30 - 378 - 12 6-9 •24 . 3u 18 - 2211 - 14 8-10 *1989 Model YearOil cooler adaptor to oil pump cover . . . . . . . . . . . . . . . .._.......................................40-5030-37REVISED: SEPT. 901:. :.


,‘,_.: ‘1: : .A’. . :


PO;;; 1987TORQUE VALUESPOWER STEERING BOX Nm ft lbClamp bolt nuts .................................................................... 14 10Ball joint nuts ....................................................................... 40 30Universal joint pinch bolt ..................................................... 35 26Drop arm nut ....................................................................... 176 130Steering wheel nut ............................................................... 38 28Sector shaft cover to steering box ....................................... 22 - 27 16-20Tie bar to steering box ......................................................... 81 60Steering box to chassis ........................................................ 81 60Power steering pump mounting ........................................... 35 26Pulley bolts, power steering pump ....................................... 8-12 6-9Union nut, inlet adaptor, power steering pump ................... 38 - 41 28 - 30Steering column bracket nuts ............................................... 27 20in lbFRONT SUSPENSIONAnti-roil bar front- Strap nyloc nuts ................................................................. 30 22- Ball link self lock nut .......................................................... 68 50- Castellated nut ................................................................... 40 30Drag link to axle ................................................................... 40 30Securing ring for mounting turret ......................................... 14 10Radius arm to chassis ........................................................... 176 130Panhard rod mounting arm to chassis .................................. 88 65Panhard rod to axle .............................................................. 88 65Panhard rod to mounting bracket ........................................ 88 65Tie bar to Panhard rod ......................................................... 88 65Radius arm to axle (front only) ............................................. 197 145REARSUSPENSIONAnti-roll bar rear- Strap nyloc nuts .................................................................- Ball link self lock nut ..........................................................- Castellated nut ...................................................................Ball joint - levelling unit to rear axle .....................................Top link to levelling unit .......................................................Top link to mounting bracket ...............................................Upper joint to levelling unit .................................................Lower joint to levelling unit .................................................Bottom link to axle ...............................................................Bottom link to chassis ..........................................................Top link bracket to rear cross member ................................Levelling unit to cross member ............................................Shock absorber to axle .........................................................30 2268 5040 30176 130115 85176 13034 2534 25176 130176 13047 3547 3537 28BRAKESBrake pipe connections to:- Brake calipers .....................................................................- Jump hoses to brackets .....................................................- Jump hose to three - way connection ...............................- Front caliper jump hoses ....................................................- Rear caliper jump hoses .....................................................- Jump hoses to calipers (all) ................................................PDWA switch (AP type master cylinder) ...............................Master cylinder to servo(AP type master cylinder and servo) .....................................Brake caliper to swivel pin housing ......................................Parking brake linkage to transfer box ...................................Brake disc to hubs ................................................................Bleed screws .......................................................................Continued12 911 - 13.5 8 -1012 911 - 13.5 8-10 .;11 - 13.5 8 -1012 91.4 - 1.7 1 - 1.313.6 - 1775 - 8826 - 3265 -'809- 1110 - 12.555 - 6519- 2448- 5980 -100REVISED: SEPT. 90


Nm ft lb in lbSupport plate and tube to valve body (AP type servo) ........ 2-3Separator shell to valve body (AP type servo) ...................... 13.5 - 17Clamp ring to servo (AP type servo) .................................... 1 - 1.616 - 20120 - 15010-15.:..Lucas Cirling servo and master cylinderServo assembly to pedal box ...............................................Brake pipes to master cylinder .............................................Master cylinder to servo .......................................................Bleed screws ........................................................................Support plate and tube to valve body (servo) ......................Separator shell to valve body (servo) ...................................Clamp ring to servo ..............................................................22 - 259-1121 - 299-112-313.5 - 171 - 1.616 - 197-815 - 2280 - 10016-20120-150IO-15.; :Wabco ABS systemBrake pipe connections to:- Hydraulic booster - Ml0 ................................................- MI2 ....................................................................................- Calipers ..............................................................................- Fourway connector rear axle ..............................................- lump hose to brackets .......................................................- lump hose female connectors ...........................................- Hydraulic pump and accumulator ......................................- PCRV - Ml0 .......................................................................- PCRV - Ml2 .......................................................................- Hydraulic booster to pedal box .........................................- Securing bolt, reservoir bracket .........................................L _12 - 16 9-1215 - 20 11 - 159-11 7-89- 11 7-811 - 13,s 8 -1011 - 13.5 8 -1012 - 16 9-1211 - 13,5 8-1012 - 14 9-1022.5 - 27,5 17-209 - 11 7-8ROAD WHEELSWheel nuts- Alloy wheels . . . . . . . . . . . . . . . . . . . . . . . . . ..._..........................................122 - 12990 - 95BODYFront and rear seat belt fixings (ALL) .................................... 20.3Front door hinges to door and body ................................... 25Rear passenger door hinges to door and body .................... 25IS1919‘.Charts below give torque values for all screws and bolts used except for those that are specifiedotherwise.SIZE METRIC SIZE UNC UNFNm h lb Nm ft lb Nm ft lbMS 5-7 3.7-5.2 114 6.8-9.5 5-7 8.1-12.2 6-9Mb 7-10 5.2-7.4 S/16 20.3-27.1 15-20 20.3-27.1 15-20MB 22-28 16.2-20.7 318 35.3-43.4 26-32 35.3-43.4 26-32Ml0 40-50 29.5-36.9 7116 67.8-88.1 50-65 67.8-88.1 50-65Ml2 80-100 59.0-73.8 II2 81.3-101.7 60-75 81.3-101.7 60-75Ml4 go-120 66.4-88.5 518 122.0-149.1 90-110 122.0-149.1 90-l IOMl6 160-200 118.0-147.5 .:REVISED: SEPT. SO


PO;;; 1987TORQUE VALUES 06 l - lTORQUE VALUESAIR CONDITIONINGNmft lbin lbCompressor hose ............................................................. 34 to 40Receiver drier hose ........................................................... 14 to 21Receiver drier switch ........................................................ 21 to 25Compressor oil filler plug ................................................. 8 to 1224 to 2910to1515to196 to 9ELECTRICALAlternator mounting bracket to cylinder head .................. 34Alternator to mounting bracket ........................................ 24Alternator to adjusting link ............................................... 24Alternator shaft nut .......................................................... 27.2 to 47.5Alternator through bolts ................................................... 4.5 to 6.2Alternator rectifier bolts ................................................... 3.4 to 3.96Amplifier module screws .................................................. 1.0 to 1.4Amplifier heat sink screws ................................................ 1 .O to 1.2Auxiliary driving lamp mounting bolts .............................. 13.6 to 20.4Distributor clampbolt ....................................................... 19 to 22Drstributor prck-up bearing plate support pillars .............. 1.0 to 1.2Distributor pick-un barrel nuts ......................................... 1 1 to I.5Drstrioutorvacuum unit .................................................... 1.7 to 2.7Spark plug ........................................................................ 19 to 21.7Starter motor to engine bolts ........................................... 40.6 to 47.4Starter motor through bolts ............................................. 6.2Solenoid fixing screws ...................................................... 6.1Solenoid battery terminal nut ........................................... 4Solenoid statter terminal nut ............................................ 3.2Reverse light switch .......................................................... 20 to 27Wiper motor yoke retaining bolts .................................... 1.35 to 1.825171720to 35lot01514 to 1614 to 163oto 3515to 204oto 5530to 359to 129to119to1110 to 1215 to 245555352812 to 16Charts below give torque values for all screws and bolts used-except for those that are specified.SIZE METRIC SIZE UNC UNFNm ft lb Nm ft lb Nm ft lbMS 5-7 3.7-5.2 II4 6.8-9.5 5-7 8.1-12.2 6-9M6 7-10 5.2-7.4 5116 20.3-27.1 IS-20 20.3-27.1 15-20M8 22-28 16.2-20.7 318 35.3-43.4 26-32 35.3-43.4 26-32Ml0 40-50 29.5-36.9 7116 67.8-88.1 SO-65 67.8-88.1 SO-65Ml2 80-100 59.0-73.8 II2 81.3-101.7 60-75 81.3-101.7 60-75Ml4 go-120 66.4-88.5 518 122.0-149.1 go-110 122.0-149.1 go-110Ml6 160-200 118.0-147.5REVISED: DEC. 87,,..


74VIRE CONNECTOR WIRING DIAGRAMIBACK-UP,A/TO BATTERY WACK)TO BRAKE (BLUE)TO TRAILER#6593BPnntKl 1” u.5 A.


PO;;; 1987GENERAL FITTING REMINDERSWORKSHOP SAFETY IS YOUR RESPONSIBILITY!THE SUGGESTIONS, CAUTIONS AND WARNINGSIN THE SECTION ARE INTENDED TO SERVE ASREMINDERS FOR TRAINED AND EXPERIENCEDMECHANICS. THIS MANUAL IS NOT A COURSEIN AUTOMOTIVE MECHANICS OR WORKSHOPSAFETY.SHOP EQUIPMENT, SHOP ENVIRONMENT, ANDTHE USE AND DISPOSAL OF SOLVENTS, FLUIDS,AND CHEMICALS ARE SUBJECr T OGOVERNMENT REGULATIONS WHICH AREINTENDED TO PROVIDE A LEVEL OF SAFETY. ITIS YOUR RESPONSIBILITY TO KNOW ANDCOMPLY WITH SUCH REGULATIONS.PRECAUTIONS AGAINST DAMAGE1. Always fit covers to protect fenders beforecommencing work in engine compartment.2. Cover seats and carpets, wear clean overallsand wash hands or wear gloves beforeworking inside vehicle.3. Avoid spilling hydraulic fluid or battery acid onpaint work. Wash off with water immediately ifthis occurs. Use Polythene sheets to protectcarpets and seats.4. Always use a recommended Service Tool, or asatisfactory equivalent, where specified.5. Protect temporarily exposed screw threads byreplacing nuts or fitting plastic caps.SAFETY PRECAUTIONS1. Whenever possible use a hoist or pit whenworking beneath vehicle, in preference tojacking. Chock wheels as well as applyingparking brake.WARNING: Do not use a pit when removing fuelsystem components.2. Never rely on a jack alone to support vehicle.Use axle stands carefully placed at jackingpoints to provide rigid support.3. Ensure that a suitable form of fire extinguisheris conveniently located.4. Check that any lifting equipment used hasadequate capacity and is fully serviceable.5. Disconnect negative (grounded) terminal ofvehicle battery.WARNING: Do not disconnect any pipes in airconditioning refrigeration system, unless trainedand instructed to do so. A refrigerant is usedwhich can cause blindness if allowed to contacteyes.6. Ensure that adequate ventilation is providedwhen volatile degreasing agents are beingused.7. Do not apply heat in an attempt to free stiffnuts or fittings; as well as causing damage toprotective coatings, there is a risk of damageto electronic equipment and brake liningsfrom stray heat.PREPARATIONI. Before removing a component, clean it and itssurrounding areas as thoroughly as possible.2. Seal off any openings exposed by componentremoval, using greaseproof paper and maskingtape.3. Immediately seal fuel, oil or hydraulic lineswhen separated, using caps or plugs, toprevent loss of fluid and entry of dirt.4. Close open ends of oilways, exposed bycomponent removal, with tapered hardwoodplugs or readily visible plastic plugs.5. When a component is removed, place it in asuitable container; use a separate container foreach component and its associated parts.6. Before dismantling a component, clean itthoroughly with a recommended cleaningagent; check that the agent is suitable for allmaterial and components.7. Clean bench and provide marking materials,labels, container5 and locking wire beforedismantling a compdnent.Continued


GENERAL FITTING REMINDERS1987 nAnrClcROVER.”2.”.’:‘...’‘.‘/’ ”.’.; .: :.,. :.‘.:DISMANTLING1. Observe scrupulous cleanliness whendismantling components, particularly whenbrake, fuel or hydraulic system parts are beingwor!:ed on. A particle of dirt or a clothfragment could cause a dangerous malfunctionif trapped in these systems.WARNING: Before using an airnecessary safety precautionsprevent personal injury, i.e.protective clothing etc.line ensure allare taken tosafety glasses,2. Blow out all tapped holes, crevices, oilwaysand fluid passages with an air line. If newO-rings are being fitted or existing O-rings aredisturbed ensure they are fitted correctly totheir respective positions.3. Mark mating parts to ensure that they arereplaced as dismantled. Whenever possibleuse marking ink, which avoids possibilities ofdistortion or initiation of cracks, liable if centrepunch or scriber are used.4. Wire together mating parts where necessary toprevent accidental interchange (e.g. rollerbearing components).5. Wire labels on to all old components whichare to be replaced with new parts or if theyrequire further inspection before being passedfor reassembly; place these parts in separatecontainers from those containing parts forrebuild.6. Do not discard a component until it has beencompared with the new part, to ensure that itscorrect replacement has been obtained.INSPECTION-GENERAL1.2.3.4.Never inspect a component for wear ordimensional check unless it is absolutely clean;a slight coating of grease can conceal anincipient failure.When a component is to be checkeddimensionally against figures quoted for it, usecorrect equipment (surface plates,micrometers, dial gauges, etc.) in serviceablecondition. Makeshift checking equipment canbe dangerous.Reject a component if its dimensions areoutside limits quoted, or if damage isapparent. A part may, however, be refitted ifits critical dimension is exactly limit size, and isotherwise satisfactory.Use ‘Plastigauge’ for checking bearingclearances. Directions for its use, and a scalegiving bearing clearances in 0.0025mm (0.0001in) steps are provided with it...:,, :.:’.:. :‘. . . ,. ;


R”d;;r; 1987GENERAL FllTlNG REMINDERS.;BALL AND ROLLER BEARINGS1.3.4.5.6.7.8.9.NEVER REFIT A BALL OR ROLLER BEARINGWITHOUT FIRST ENSURING THAT IT IS IN AFULLY SERVICEABLE CONDITION.Remove all traces of lubricant from bearingunder inspection by washing in a suitabledegreaser; maintain absolute cleanlinessthroughout operations.2. Inspect visually for markings of any form onrolling elements, raceways, outer surface ofouter rings or inner surface of inner rings.Reject any bearings found to be marked, sinceany marking in these areas indicates onset ofwear.Holding inner race between finger and thumbof one hand, spin outerrace and check that itrevolves absolutely smoothly. Repeat, holdingouter race and spinning inner race.Rotate outer ring gently with a reciprocatingmotion, while holding inner ring; feel for anycheck or obstruction to rotation, and rejectbearing if action is not perfectly smooth.Lubricate bearing generously with lubricantappropriate to installation.Inspect shaft and bearing housing fordiscoloration or other marking suggesting thatmovement has taken place between bearingand seatings. (This is particularly to beexpected if related markings were found inoperation 2).Ensure that shaft and housing are clean andfree from burrs before fitting bearing.If one bearing assembly of a pair shows animperfection it is generally advisable to replaceboth with new bearings; an exception couldbe made if the faulty bearing had covered alow mileage, and it could be established thatdamage was confined to it only.When fitting bearing to shaft, apply force onlyto inner ring of bearing, and only to outer ringwhen fitting into housing. (Refer to ST1042M).10. In the case of grease lubricated bearings (e.g.hub bearings) fill space between bearing andouter seal with recommended grade of greasebefore fitting seal.11. Always mark components of separablebearings (e.g. taper roller bearings) indismantling, to ensure correct reassembly.Never fit new rollers in a used outer ring,always fit a complete new bearing assembly.OIL SEALS1.2.3.4.5.NOTE: Ensure that the seal running track isfree from pits, scores, corrosion andgeneral damage prior to fitting replacementseal.Always fit new oil seals when rebuilding anassembly.Carefully examine seal before fitting to ensurethat it is clean and undamaged.Coat the sealing lips with clean grease; packdust excluder seals with grease, and heavilygrease duplex seals in cavity between sealinglips.Ensure that seal spring, if provided, is correctlyfitted.Place lip of seal towards fluid to be sealed andslide into position on shaft, using fitting sleevewhen possible to protect sealing lip fromdamage by sharp corners, threads or splines. Iffitting sleeve is not available, use plastic tubeor tape to prevent damage to sealing lip.ST1038M Y-ContinuedJST1042M'.\'. q, :.I.: :.I.. .I,3


GENERAL FITTING REMINDERS;; :6. Grease outside diameter of seal, place squareto housing recess and press into position,using great care and if possible a ‘bell piece’to ensure that seal is not tilted. (In some casesit may be preferable to fit seal to housingbefore fitting to shaft). Never let weight ofunsupported shaft rest in seal.IOINTS AND JOINT FACES4.5.6.Always use correct gaskets where they arespecified.llse jointing compound only whenrecommended. Otherwise fit joints dry.When jointing compound is used, apply in athin uniform film to metal surfaces; take greatcare to prevent it from entering oilways, pipesor blind tapped holes.Remove all traces of old jointing materialsprior to reassembly. Do not use a tool whichcould damage joint faces.Inspect joint faces for scratches or burrs andremove with a fine file or oil stone; do notallow removed material or dirt to enter tappedholes or enclosed parts.Blow out any pipes, channels or crevices withcompressed air, fit new ‘0’ rings or sealsdisplaced by air blast.FLEXIBLE HYDRAULIC PIPES, HOSES::.” ,.7.8.If correct service tool is not available, use asuitable drift approximately 0.4mm (0.015 in)smaller than outside diameter of seal. Use ahammer VERY GENTLY on drift if a press isnot suitable.Press or drift seal in to depth of housing ifhousing is shouldered, or flush with face ofhousing where no shoulder is provided.Ensure that the seal does not enter thehousing in a tilted position.NOTE: Most cases of failure or leakage ofoil seals are due to careless fitting, andresulting damage to both seals and sealingsurfaces. Care in fitting is essential if goodresults are to be obtained. NEVER use a sealwhich has been improperly stored orhandled, such as hung on a hook or nail.1.2.3.4.5.6.7.8.9.11.12.Before removing any brake or power steeringhose, clean end fittings and area surroundingthem as thoroughly as possible.Obtain appropriate plugs or caps beforedetaching hose end fittings, so that ports canbe immediately covered to exclude dirt.Clean hose externally and blow through withairline. Examine carefully for cracks, separationof plies, security of end fittings and externaldamage. Reject any hose found faulty.When refitting hose, ensure that nounnecessary bends are introduced, and thathose is not twisted before or during tighteningof union nuts.Containers for hydraulic fluid must be keptabsolutely clean. :Do not store brake fluid in an unsealedcontainer. It will absorb water, and fluid in thiscondition would be dangerous to use due to alowering of its boiling point.Do not allow brake fluid to be contaminatedwith mineral oil, or use a container which haspreviously contained mineral oil.Do not re-use brake fluid bled from system.Always use clean brake fluid to clean hydrauliccomponents.10. Fit a cap to seal a hydraulic unio and a plugto its socket after removal to pLvent ingressof dirt.Absolute cleanliness must be observed withhydraulic components at all times.After any work on hydraulic systems, inspectcarefully for leaks underneath the vehicle while ‘;a second operator applies maximum pressureto the brakes (engine running) and operates ,, .-.the steering. i: I


;;^d;;; 1987GENERAL FllTlNG REMINDERSFUEL SYSTEM HOSESCAUTION: ALL FUEL HOSES ARE MADE UP OFTWO LAMINATIONS, AN ARMOURED RUBBEROUTER SLEEVE AND AN INNER VITON CORE. IFANY OF THE FUEL SYSTEM HOSES HAVE BEENDISCONNECTED, IT IS IMPERATIVE THAT THEINTERNAL BORE IS INSPECTED TO ENSURE0 .THATTHE VITON LINING HAS NOT BECOMESEPARATED FROM THE AMOURED OUTERSLEEVE. A NEW HOSE MUST BE FITTED IFSEPARATION IS EVIDENT.I0Q \ I \XMETRIC NUT IDENTIFICATIONA nut with an IS0 metric thread is marked onone face or on one of the flats of the hexagonwith the strength grade symbol 8, 12 or 14.Some nuts with a strength 4, 5 or 6 are alsomarked and some have the metric symbol Mon the flat opposite the strength grademarking.A clock face system is used as an alternativemethod of indicating the strength grade. Theexternal chamfers or a face of the nut ismarked in a position relative to theappropriate hour mark on a clock face toindicate the strength grade.A dot is used to locate the 12 o’clock positionand a dash to indicate the strength grade. Ifthe grade is above 12, two dots identify theI 2 o’clock oosition.RR2302MMETRIC BOLT IDENTIFICATION1. An IS0 metric bolt or screw, made of steeland larger than 6 mm in diameter can beidentified by either of the symbols IS0 M orM embossed or indented on top of the head.2. In addition to marks to identify themanufacture, the head is also marked withsymbols to indicate the strength grade, e.g.8.8, 12.9 or 14.9, where the first figure givesthe minimum tensile strength of the boltmaterial in tens of kgflmm’.3. Zinc plated IS0 metric bolts and nuts arechromate passivated, a gold-bronze colour.STlO36MContinuedREVISED: JULY 885Z.‘.


lid GENERALFl-l-l-INC REMINDERS1987 r;;&KEYS AND KEYWkYS1. Remove burrs from edges of keyways with afine file and clean thoroughly beforeattempting to refit key.2. Clean and inspect key closely; keys areTABsuitable for refitting only if indistinguishablefrom new, as any indentation may indicate theonset of wear.WASHERS1. Fit new washers in all places where they areused. Always fit a new tab washer.2. Ensure that the new tab washer is of the samedesign as that replaced.COlTER PINSI. Fit new cotter pins throughout when replacingany unit.2. Always fit cotter pins where cotter pins wereoriginally used. Do not substitute springwashers: there is always a good reason for theuse of a cotter pin.3. All cotter pins should be fitted as shownunless otherwise stated.SCREWTHREADS‘..,1. Both UNF and Metric threads to IS0 standards ,:are used. See below for thread identification.2. Damaged threads must always be discarded.Cleaning up threads with a die or tap impairsthe strength and closeness of fit of the threadsand is not recommended.3. Always ensure that replacement bolts are atleast equal in strength to those replaced.4. Do not allow oil, grease or jointing compoundto enter blind threaded holes. The hydraulicaction on screwing in the bolt or stud couldsplit the housing.5. Always tighten a nut or bolt to therecommended torque value. Damaged orcorroded threads can affect the torquereading.6. To check or re-tighten a bolt or screw to aspecified torque value first loosen a quarter ofa turn, then re-tighten to the correct value.7. Oil thread lightly before tightening to ensure afree running thread, except in the case ofthreads treated with sealant/lubricant (seesection 06 - Torque Values), and self-lockingnuts.UNIFIED THREAD IDENTIFICATIONST1030MNUTSBoltsA circular recess is stamped in the uppersurface of the bolt head.NutsA continuous line of circles is indented on oneof the flats of the hexagon, parallel to the axisof the nut.Studs, Brake Rods, etc.The component is reduced to the corediameter for a short length at its extremity...-__When tightening a slotted or castellated nutnever loosen it back to insert cotter pin orlocking wire except in those recommendedcases where this forms part of an adjustment.If difficulty is experienced, alternative washersor nuts should be selected, or washerthickness reduced.Where self-lccking nuts have been removed itis advisable to replace them with new ones ofthe same type.NOTE: Where bearing pre-load is involvednuts should be tightened in accordancewith special instructions.ST1039MLLOCKING WIREI. Fit new locking wire of the correct type for allassemblies incorporating it.2. Arrange wire so that its tension tends totighten the bolt heads, or nuts, to which it isfitted.6 REVISED: JULY 88


iI,III;;“d;‘;;i 1987 LUBRICANTS, FLUIDS AND CAPACITIES 109 1RECOMMENDED LUBRICANTS AND FLUIDSAMBIENTTEMPERATURE‘CCOMPONENT SPECIFICATION -30 -20 -10 0 10 20 30 40 50“F-22 -4 +14 +32 50 68 86 104 122Viscosity,fngine Use oils to API SW/20 fservice levels SW/30 ) /SE or SF or SW/40 )SE/CC orSF/CC 1 ow/30,.::low/40 )low/50 )15w/40 )15w/50 )!:-y---+!2OW/40 )2OW/50 ): ._I,:AutomaticgearboxATF Dexron IIDViscosityrransfer !;earboxfLT230) APICL4 or CL5 90 EP‘inal driveJr-titsMIL-L-2105 orjwivel piniousings MIL-L-2105B 80W EP 1RcxlL3.L $7L 3534>ower steeringATF Dexron IIDi3org Warner ATF Dexron IID:ransfer gearbox ATF M2C 33CATF Texaco 4291A Universali :3rake reservoir Brake fluid must have a minimum ; j j j i j ;boiling point of 260°C (500°F) andIcomply with FMVSSI116IDOT 4ubricationGpples (hubs,>all joints, etc.)i i i i jNLCI-2 multipurpose lithium based i : : ]grease,i ; j ; ; ; ; ! ;REVISED: MARCH 90 1


.‘,r-l 09 LUBRICANTS, FLUIDS AND CAPACITIES1987 ;;^d;‘;l;.’Engine coolingsystemUse an ethylene glycol based anti-freeze (containing no methanol)with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure theprotection of the cooling system against frost and corrosion in all seasons. Use one partanti-freeze to one part water for protection down to -36°C (-33°F).IMPORTANT: Coolant soluiion must not fall below proportions one par1 anti-freeze tothree parts water, i.e. minimum 25% anti-freeze in coolant otherwise damage to engine isliable to occur.Battery lugs,Earthing surfaceswhere paint has beenremovedPetroleum jelly.NOTE: Do not use Silicone GreaseAir Conditioning METHYLCHLORIDE REFRIGERANTS MUST NOT BE USEDSystem Refrigerant Use only with refrigerant 12. This includes ‘Freon 12’ and ‘Arcton 12’:CompressorOilShell Clavus 68 BP Energol LPT68 Sunisco 4CSTexaco Caoella E Wax/Free 68. Castro1 lcematic 99_,“,ABS Sensorbush-rearSilicone grease: Staborags NBU - Wabco 830 502,0634Wacker chemie 704 - Wabco 830 502.0164Kluber CL301,’ANTI-FREEZEENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTIONCONCENTRATIONLOWERTEMPERATURELIMITV8 (aluminium)One part anti-freezeOne part water 50%.I_’Complele protectionVehicle may be driven away immediately from cold-33“F-36OCSafe limit protectionCoolant in mushy state. Engine may be started and driven away after warm-up period-4lOC--42°Flower protectionPrevents frost damage to cylinder head, block and radiator. Thaw out before starting engine-47%-53°F.,,‘_‘, .:,2 REVISED: MARCH 90


‘,LUBRICANTS, FLUIDS AND CAPACITIES 109 1Capacilies fappr0x.Y Lilres Imperial unit US unit.’ :5Engine sump and filter from dry 5.68 10 pints12.0 pintsGearbox from dry-automatic ZF9.1 16 pints20 pintsLT230 Transfer gearbox from dry2.5 4.4 pints5.3 pintsFront axle from dry1.7 3.0 pints3.6 pintsFront axle swivel pin housing (each)0.35 0.6 pints 0.7 pintsRear axle from dry 1.7 3.0 pints 3.6 pintsPower steering box and reservoir 2.9 5.0 pints 6.0 pintsCooling system 11.4 20 pint 24 pintsFuel tank 76.4 16.8 gallons 20 gallonsFuel tank (91 model year)81.8 18 gallons 21.4 gallonsBorg Warner transfer gearbox from dry 1.7 3.0 pints 3.6 pints:.NOTE:* All levels must be checked by dipstick or level plugs as applicable.*::.:’When draining oil from the ZF automatic gearbox, oil will remain in the torque converter,refill to high level on dipstick only.;.‘.”‘.’.’ :,:;.::j*:;.:. . . . . I,. ..LUBRICATION PRACTICEThe engine is filled with special oil to protect it during the running-in-period. The engine must be drainedafter 1600 km (1,000 miles) and refilled with an appropriate lubricant.Use a high quality oil of the correct viscosity range and service classification in the engine duringmaintenance and when topping up. The use of oil not to the correct specification can lead to high oil andfuel consumption and ultimately to damaged components.i.Oil to the correct specification contains additives which disperse the corrosive acids formed by combustionand prevent the formation of sludge which can block the oilways. Additional oil additives should not beused. Always adhere to the recommended servicing intervals.WARNING: Many liquids and other substances used in motor vehicles are poisonous and should underno circumstances be consumed and should be kept away from open wounds. These substances amongothers include anti-freeze, brake fluid, fuel, windscreen washer additives, lubricants and variousadhesives.FUEL REQUIREMENTSThe engine is designed to use only unleaded fuel. Unleaded fuel must be used for the emission controlsystem to operate properly. Its use will also reduce spark plug fouling, exhaust system corrosion and engineoil deterioration.)’*I‘,),.,h‘... ,: .;..:..,I:,.3Using fuel that contains lead will result in damage to the emission control system and could result in loss ofwarranty coverage. The effectiveness of the catalysts in the catalytic converters will be seriously impaired ifleaded fuel is used. The vehicle is equipped with an electronic fuel injection system, which includes twooxygen sensors. Leaded fuel will damage the sensors, and will deteriorate the emission control system.Federal regulations require that pumps delivering unleaded fuel be labelled UNLEADED. Only these pumpshave nozzles which fit the filler neck of the vehicle fuel tank.:In the United States, Federal law also requires that fuel octane ratings be posted on thel(pumps. The Cost ofLiving Council Octane Rating (CLC) or Anti-knock Index (AKI) shown is an average of Research OctaneNumber (RON) and Motor Octane Number (MON). Fuel with a CLC or AKI rating of at least 87 should beused.Continued. c,:.: .,,,’REVISED: SEPT 90.,.


1988 Model Year Vehicles: Premium unleaded gasoline should be used with a CLC or AKI rating of 90 or 91(95 or 96 RON), use of the higher of these ratings will enhance engine smoothness and overall performance.1989 Model Year Vehicles: Premium unleaded gasoline must be used with a CLC or AKI rating of 90minimum (95 RON). Fuel used other than that specified for the Model Year could seriously impair vehicleperformance.Using unleaded fuel with an octane rating lower than stated above can cause persistent, heavy ‘spark knock’(‘spark knock’ is a metallic rapping noise). if severe, this can lead to engine damage. If a heavy spark knock isdetected even when using fuel of the recommended octane rating, check the ignition timing system.CAUTION: Do not use oxygenated fuels such as blends of methanol/ gasoline or ethanol/gasoline (e.g.%asohol’). Take care not to spill fuel during refueiling.J4 REVISED: SEPT 90;, . . ‘.


-K”d;‘;r; 1987-88-89MAINTENANCERANGE ROVER REQUIRED MAINTENANCE - 49 STATES AND CALIFORNIAFIRST 1,000 MILE SERVICE ONLYRenew engine oilCheck front wheel alignmentRenew transfer box oil (LT230)Check/top up transfer box oil (Borg Warner)Renew front axle oilRenew rear axle oilRenew steering swivel oilCheck/top up power steering fluidCheck/top up automatic transmission fluidCheck for oil/fluid leaks from:- Suspension, dampersand self levelling unit, engine and transmissionunits, front and rear axlesCheck brake pipes/unions for security, chafing, leaksand corrosionCheck power steering system for leaks, hydraulicpipes/unions for security, chafing and corrosionCheck PCV system for leaks and hoses for securityand condition (Positive crankcase ventilation).Check operation of throttle mechanical linkage andtransmission cableCheck ignition wiring and HT leads for security, andfrayingCheck/adjust all drive beltsCheck operation of a!l instruments fuel andtemperature gauges, warning indicators, lamps,horns and audio unitCheck operation of front and rear screen andheadlamp wash/wipersCheck operation of rear view mirrors and forsecurity, cracks and crazingCheck condition and security of seats, seat beltmountings, belts and buckles.‘. ”Check fuel system for leaksCheck exhaust system for leaks, security anddamageCheck cooling and heater systems for leaks, hosesfor security and condition Check tyres comply with ManufacturersspecificationCheck security and operation of park brakeCheck tyres for cuts, lumps, bulges, uneven wear,Check foot brake operationtread depth and road wheels for damageCheck condition and security of steering unit, jointsand gaitersCheck/adjust steering boxCheck and adjust tyre pressures including spareCheck and tighten road wheel retaining nutsRANGE ROVER REQUIRED EMISSION MAINTENANCE - CALIFORNIAINTERVALS MILES X .lOOORenew engine oil7.5 15 22.5 30 37.5 45. . . . . .Renew engine oil filler. . . . . .I Renew spark plugs I I I I*/‘ ICheck exhaust system for leaks, security and damage • • • • • •Check condition of driving belts-adjust if required • • • • • •.c .CALIFORNIA MODELS - FOR MAINTENANCE AFTER 45,000 MILES WE RECOMMEND THAT THE 49STATES REQUIRED MAINTENANCE BE CARRIED OUT IN ADDITION TO THE RECOMMENDEDMAINTENANCE.ContinuedREVISED: SEPT. 88 1:


MAINTENANCE 110 1RANGEROVER RECOMMENDED MAINTENANCEAAINTENANCE INTERVALS MILES X 1000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 62.5 90 97.5 105Iheck/top up transfer box oil . . . . . . . . . . .lenew transfer box oil . . .Iheck/top up front axle oil . . . . . . . . . . .tenew front axle oil . . .ZhecWtop up rear axle oil . . . . . . . . . . .tenew rear axle oil . . .Ihectitop up steering swivel housing oil . . . . . . . . . . .Zenew steering swivel housing oil . . .7enew automatic transmission fluid . . .Check battery conditionCheck ignition wiring and HT leads for security,fraying, chafing, deteriorationContinuedREVISED: MAY 89 3 :. ,.’. ‘2.


,r-l 10 MAINTENANCERANGE ROVER RECOMMENDED MAINTENANCEContinuedjust rgnrtron trmrngCheck tyres comply with Manufacturer’sspecification . . . . . . . . . . . . . .Check tyres for cuts, lumps, bulges, uneven wear,tread depth and road wheels for damage . . . . . . . . . . . . . .Check/adjust tyre pressures including spare . . . . . . . . . . . . . .Check/adjust headlamp and auxiliary lamp alignment • • • • • • •Check operation of all instruments, gauges,warning indicators, lamps, horns andstereo unit . . . . . . . . . . . . . .Check operation of front and rear screen andheadlamp wash/wipers . . . . . . .Clear sunroof drain tubes - if applicable . . . . . . . . . . . . . .Check operation of all doors, hood, and tailgatelocks and window controls . . . . . . . . . . . . . .Lubricate all locks (not steering lock)and door check mechanisms . . . . . . .Check operation of heater and air conditioningsystems . . . . . . .Check brake pipes/unions for security, chafing,leaks and corrosion . . . . . . . . . . . . . .Check power steering system for leaks, hydraulicpipes/unions for security, chafing and corrosion • • • • • • • • • • • • • •Check fuel lines/hoses for leaks . . . . . . . . . . . . . .Check cooling and heater systems for leaks,hoses for security and condition . . . . . . ..’Check/top up cooling system . . . . . . . . . . . . . .1qInspect brake pads for wear, calipers for leaksand discs for condition . . . . . . . . . . . . . .Check security and operation of parking brake • • • • • • • • • • • • • •Lubricate parking brake mechanical linkage . . . . . . . . . . . . . .Lubricate drive shaft universal joints . . . . . . . . .• I* • • •Lubricate drive shaft sealed sliding joints . . . .4 REVISED: MAY 89‘, ;. :‘. ::::


.R”d;;r; 1987MAINTENANCE,I’,.,’:.:,..,: i. . .2. Raise the front road wheels off the groundhigh enough to enable an axle stand to beinstalled under the left hand axle tube.3. Position an axle stand under the right handaxle tube, carefully lower the floor jack untilthe axle sits securely on both axle stands,remove the floor jack.4. Before commencing work on the underside ofthe vehicle recheck the security of the vehicleon the stands.5. Reverse the procedure when removing thevehicle from the stands.DYNAMOMETER TESTING OF PERMANENTFOUR-WHEEL DRIVE VEHICLES (Vehicles fittedwith LT230 transfer gearbox)Four-wheeldynamometersProvided that front and rear rollers of theequipment are rotating at the same peripheralspeed and that normal workshop safety standardsare observed, there is no speed restriction on theuse of four-wheel (double axle) roller rigs for thetesting of permanent four-wheel drive vehicles.Raise the rear of the vehicle1. Position the cup of the hydraulic arm underthe differential casing.2. Raise the vehicle high enough to enable axlestands to be installed under the left and righthand axle tubes.3. Lower the floor jack until the axle sits securelyon the axle stands, remove the floor jack.4. Before commencing work on the underside ofthe vehicle recheck the security of the vehicleon the stands.5. Reverse the procedure when removing thevehicle from the stands.HYDRAULIC VEHICLE HOIST (FOUR POST)Use only a ‘drive on’ type hoist which supports thevehicle by its own road wheels. If a ‘wheel-free’condition is required, use a ‘drive on’ hoistincorporating a ‘wheel-free’ system that supportsunder the axle casings. Alternatively, place thevehicle on a firm, flat floor and support on axlestands.TWO POST VEHICLE HOISTSThe manufacturer of RANGE ROVER VEHICLESDOES NOT recommend using ‘Two Post’ hoiststhat employ four adjustable support arms. Theseare NOT considered safe for Range Rovervehicles.If the vehicle is installed on a Two Post hoist theresponsibility for the safety of the vehicle andsafety of the personnel performing serviceoperations is in the hands of the ServiceProvider.NOTE: The centre differential must not belocked during brake testing. The brakeservo-assistance will not be maintained withoutthe engine running.Two-wheel dynamometersTesting of a four-wheel drive vehicle on a singleaxle roller rig must be restricted to a maximumroller peripheral speed of 5kph (3 mph) with thecentre differential unlocked and the transfergearbox in neutral. For tests above this speed on asingle axle rig, the centre differential must belocked and the drive shaft to the stationary axlemust be removed.TOWINGCAUTION: Range Rovers have permanentfour-wheel drive. Should the vehicle need to betowed, the following instructions must beadheredto:Towing the vehicle on all four wheels with driveroperating steering and brakes.1. Insert the ignition key and turn to the auxiliaryswitch position '1' to release the steering lock.2. Select neutral in main gearbox and transfergearbox with the differential unlocked.3. Towing rope, chain or cable should be fittedto the towing eye that protrudes out of thefront of the spoiler immediately below thefront bumper.4. Release the parking brake.Continued I(t!.$REVISED: SEPT. 887i .’


MAINTENANCE1987 MNGtROVERTRANSPORTING THE VEHICLE BY TRAILERLashing eyes are provided on the front and rear ofthe chassis side members, to facilitate the securingof the vehicle to a trailer or other means oftransportation.CAUTION: Underbody components must not beused as lashing points.Install the vehicle on the trailer and apply theparking brake. To prevent damage occurring to theparking pawl of the automatic gearbox selectneutral ‘N’ gear in main gearbox.FRONT OF CHASSIS. . ...*CAUTION: The brake servo and power assistedsteering system will not be functional withoutthe engine running. Greater pedal pressure willbe required to apply the brakes, the steeringsystem will require greater effort to turn thefront road wheels.The vehicle tow connection should be used onlyin normal road conditions, ‘snatch’ recoveryshould be avoided.Suspended tow by breakdown vehicleCAUTION: To prevent damage to the vehicle thefront or rear drive shaft MUST BE removed,dependent upon which axle is being trailed.1.2..y.3.Mark the drive shaft drive flanges at thetransfer gearbox and axle differential withidentification lines to enable the drive shaft tobe refitted in its original position,Remove the fixings from the differential driveflange to drive shaft/transfer box drive flangeto drive shaft, withdraw the shaft completefrom beneath the vehicle.If the front axle is to be trailed it is necessaryto insert the ignition key and turn to theauxiliary switch position '1' to release thesteering lock.REAR OF CHASSISCAUTION: The steering wheel and/or linkagemust be secured in a straight ahead position.DO NOT use the steering lock mechanism forthis purpose.. .‘.. . . . . ..>,‘I_, ,.,..8 .REVISED: SEPT. 88


;;;;; 1987MAINTENANCEJUMP STARTINGWARNING: Hydrogen and oxygen gases areproduced during normal battery operation. Thisgas mixture can explode if flames, sparks orlighted tobacco are brought near the battery.When charging or using a battery in an enclosedspace, always provide ventilation and shield youreyes.Keep out of reach of children. Batteries containsulphuric ‘acid. Avoid contact with skin, eyes, orclothing. Also, shield your eyes when workingnear the battery to protect against possiblesplashing of the acid solution. In case of acidcontact with skin, eyes, or clothing, flushimmediately with water for a minimum of fifteenminutes. If acid is swallowed, drink largequantities of milk or water, followed by milk ofmagnesia, a beaten egg, or vegetable oil.SEEK MEDICAL AID IMMEDIATELY.To Jump Start- Negative Ground BatteryWARNING: To avoid any possibility of injury useparticular care when connecting a boosterbattery to a discharged battery.1. Position the vehicles so that the jumper leadswill reach, ensuring also that the vehicles DONOT TOUCH, alternatively a fully chargedslave battery may be used positioned on thefloor adjacent to the vehicle.2. Ensuring that the ignition and all electricalaccessories are switched off, that the parkingbrake is applied and neutral (N) or park (P) isselected in main gearbox, connect the jumpercables as follows;A. Connect one end of the first jumpercable to the positive (+) terminal of thebooster battery.B. Connect the other end of the firstjumper cable to the positive ( + ) terminalof the discharged battery.C. Connect one end of the second jumpercable to the negative (-) terminal of thebooster battery.D. Connect the other end of the secondjumper cable to the rear lug of the airconditioning compressor, keep thejumper lead well away from any enginemoving parts ie pullies, drive belts andfan blade assembly. NOT TO THENEGATIVE (-) TERMINAL OF THEDISCHARGED BATTERY.WARNING: Making the final cable connectioncould cause an electrical arc which if made nearthe battery could cause an explosion.3. If the booster battery is installed in anothervehicle, start the engine of that vehicle andallow it to idle.4. Start the engine of the vehicle with thedischarged battery, following the startingprocedure in the Owners’Manual.CAUTION: If the vehicle fails to start within amaximum time of I? seconds, switch the ignitionoff and investigate the- cause. Failing to followthis instruction could result in irrepairabledamage to the catalysts.5. Remove the positive (+) jumper cable fromthe positive terminals of both the boosterbattery and discharged baltery.6. Likewise remove the negative t-J jumpercable.REVISED: SEPT. 88 9


MAINTENANCE1987 r(ANLtROVERLUBRICATIONThis first part of the maintenance section coversrenewal of lubricating oils for the major units of thevehicle and other components that requirelubrication, as detailed in the ‘MaintenanceSchedules’. Refer to Section 09 for Capacities andRecommended Lubricants.Vehicles operating under severe conditions of dust,sand, mud and water should have the oils changedand lubrication carried out at more frequentintervals than that recommended in themaintenance schedules.Draining of used oil should take place after a runwhen the oil is warm. Always clean the drain andfiller-level plugs before removing. In the interests ofsafety disconnect the vehicle battery to prevent theengine being started and the vehicle movedinadvertently, while oil changing is taking place.Allow as much time as possible for the oil to draincompletely except where blown sand or dirt canenter the drain holes. In these conditions clean andrefit the drain plugs immediately the main bulk ofoil has drained.Where possible, always refill with oil of the makeand specification recommended in the lubricationcharts and from sealed containers.RENEW ENGINE OIL AND FILTERDRAIN THE OILBefore changing the oil ensure that the vehicleis level on either hoist or ground.Run the engine to warm the oil; switch off theignition and disconnect the battery for safety.Place an oil tray under the drain plug.Remove the drain plug in the bottom of thesump at the left-hand side. Allow oil to drainaway completely. Fit new copper washer andreplace the plug, tighten to the correct torquevalue.Fit new oil filter5. Remove the engine under-tray if the vehicle isa 7989 model year (See Section 76, page 60).Place an oil tray under the engine.NOTE: 1989 model year vehicles have an engineoil cooler. The oil cooler adaptor is secured tothe oil pump cover, see RR2616E.6.7.Unscrew the filter counter -clockwise, using astrap wrench as necessary.Clean the oil pump mating face (1989 Models:oil cooler adaptor mating face) and coat therubber washer of the new filter with cleanengine oil, screw the filter on clockwise untilthe rubber sealing ring touches the machinedface, tighten a further half turn by hand only.DO NOT over-tighten.RR2616E1 0 REVISED: SEPT. 88.,. .’


o;;; 1987MAINTENANCERefill sump with oil8.9.Check that the drain plug is tight.Clean the outside of the oil filler cap, removeit from the extension filler neck and clean theinside.3. Inject the approximate quantity of therecommended oil until it reaches the level/fillerplug hole. Fit the level/filler plug and tightento the correct torque value, do notover-tighten, wipe away any surplus oil.10.11.Pour in the correct quantity of new oil of thecorrect grade from a sealed container to thehigh mark on the dipstick and firmly replacethe filler cap. DO NOT FILL ABOVE ‘HIGH’MARK. Reconnect the battery.Run the engine and check for leaks from thefilter. Stop the engine, allow the oil to runback into the sump for a few minutes, thencheck the oil level again and top up ifnecessary.RENEW MAIN AND TRANSFER GEARBOX OILSDRAIN AND RENEW LT230 TRANSFER GEARBOXOIL1.2.Before changing the oil ensure that the vehicleis level on either hoist or ground. Place acontainer under the gearbox to catch the oldoil. Disconnect the battery.Remove the drain and level/filler plugs andallow the oil to drain. Fit the drain plug usinga new washer, if necessary, and tighten to thecorrect torque value. Do not over-tighten.RENEW ZF AUTOMATIC GEARBOX FLUIDBefore changing the oil ensure that the vehicleis level on either hoist or ground. Obtain asuitable container to drain the gearbox fluidinto. Disconnect the battery.Remove the gearbox dipstick located at therear of the right hand rocker cover, to aid oildrainage. Release the plug from the bottom ofthe sump and allow time for the fluid to drain.Refit the plug using a new sealing washer andtighten to the correct torque value. Do notover-tighten.Continued11:.:


MAINTENANCE1987 r;;;I;; ;’.::’ :‘. ”Refill ZF Automatic Gearbox and Check Fluidlevel.NOTE: The fluid level in the ZF automaticgearbox is checked when the fluid is coldand the engine idling in neutral gear.Refitting10. Fit two new ‘0’ rings to the oil screen using alight grease for ease of assembly.11. Fit the suction tube to the oil screen..‘.Ensure the vehicle is on level ground.Refill or top-up with the correct quantity andgrade of fluid (see Lubricants and FluidsSection 09) at the combined filler/dipsticktube.Reconnect the battery, start and run theengine, ensure that the fluid level registersbetween the minimum and maximum levelmarkings on the dipstick.‘-L3.16% - 2,16: .:OIL SCREEN REPLACEMENT ZF AUTOMATICGEARBOXRemoving1. Place the vehicle on a hoist or over a pit,open the hood and disconnect the batteryleads.2. From underneath the vehicle drain the gearboxusing a suitable container.3. Discard the oil pan plug seal ring.4. Remove the filler/level tube from the oil pan.5. Remove the six retaining plates and bolts.6. Remove the oil pan and discard the gasket.7. Using TX27 Torx bit remove the three screwswhich hold the oil screen.8. Remove the oil screen and discard the ‘0’rings.9. Separate the oil screen from the suction tubeand discard the ‘0’ ring and oil screen.12.13.14.15.16.17.18.19.Fit the oil screen to the control unit andsecure with three bolts using TX27 Torx bittighten to the specified torque value.Refit the oil pan using a new gasket.Secure using the six retaining plates and bolts(two straight and four corner plates), tightento the specified torque value.Reconnect the oil level/filler tube.Fit oil pan plug using a new seal.Connect the battery leads.Fill the gearbox with the correct oil throughthe filler/level tube located within the enginebay (see Lubricants and Fluids Section 09).Ensuring the vehicle is on level ground withthe park-brake applied, check oil level whileengine is running at idle with neutral selected.12 .:


f;^d;‘;r; 1987MAINTENANCE 110 1POWER STEERING-FLUID RESERVOIRClean and remove the reservoir cap, wipe thedipstick which is incorporated into the cap andrefit the cap. Remove the cap again and checkthe fluid level is up to the high mark on thedipstick.ff necessary top-up with a recommended fluid(see Lubricants and fluids Section 09).Refit the cap.RENEW FRONT AND REAR AXLE OILThe vehicle must be level. Place a containerunder the axle to be drained.Using a wrench with a 13mm (0.5 in) squaredrive remove the drain and filler/level plugsfrom the axle and allow the oil to draincompletely. Clean and refit the drain plug.Inject new oil of a recommended make andgrade until it reaches the level hole. Clean andrefit the filler/level plug and wipe away anysurplus oil.RR2031E \\13:.


MAINTENANCE1987 ;;“d;;;RENEW SWIVEL PIN HOUSING OILThe vehicle must be level. Place a containerunder each swivel housing to catch the oldoil.Remove the drain and level plugs and allowthe oil to drain completely, clean and refit thedrain plug.Remove the filler plug and inject therecommended make and grade of oil until oilreaches the level hole.Clean and refit the level and filler plugs, wipeaway any surplus oil.LUBRICATE FRONT AND REAR DRIVE SHAFTUNIVERSAL AND SLIDING JOINTS1.2.Clean all the grease nipples on the front andrear drive shafts.Charge a low pressure hand-grease gun withgrease of a recommended make and gradeand apply to the grease nipples at the frontand rear drive shaft universal and sliding joints.RR2032E‘.


,‘,.’FILTERSFUEL LINE FILTER, :.;.:AIR CLEANER ELEMENTRemove and refitRemoving1.2.3.4.5.6.7.8.9.Release the two clips securing the air cleanerto the airflow sensor.Release the two nuts and bolts securing the aircleaner to the left hand valance mountingbracket.Detach the airflow sensor from the air cleaner,and lay carefully to one side.Detach the air cleaner from the centremounting bracket and withdraw from theengine compartment.Remove the large ‘0’ ring from the outlettube of the air cleaner, inspect for condition,fit a new ‘0’ ring if in poor condition.Unclip the three catches securing the inlettube to the air cleaner canister and removethe inlet tube.Remove the nut and end plate securing the aircleaner element in position.Withdraw the air cleaner element and discard.Inspect the dump valve for condition andcheck that it is clear of obstructions.WARNING: The spilling of fuel is unavoidableduring this operation. Ensure that all necessaryprecautions are taken to prevent fire andexplosion.1. Depressurize the fuel system. (Refer to FuelInjection System - Section 19)2. The fuel line filter is located on the right handchassis side member forward of the fuel tankfiller neck. Access to the filter is gainedthrough the right hand rear wheel arch.3. Thoroughly clean the immediate area aroundthe hose connections to prevent ingress offoreign matter into the fuel system.4. Loosen the two hose clamps nearest the filterto enable the hoses to be removed from thefilter canister. Plug the end of the hoses toprevent ingress of dirt.5. Release the securing bolt and bracket andremove the filter from the chassis sidemember.;;RR2034EFit new filterRRl854ERefitting10. Fit new element and secure in position.11. Refit the inlet tube to the air cleaner canister.12. Refit the air cleaner to the mounting bracketand tighten the two nuts and bolts.13. Clip the air flow sensor to the air cleaner.6. Fit a new filter observing the direction of flowarrows stamped on the canister.7. Start the engine and inspect for fuel leaksaround the hose connections.J,.’: ,: .:I:;:: ‘,,.’,_.‘.::15


MAINTENANCE1987 IaNbeROVERCHARCOAL CANISTER1. Disconnect from the canister:(i) Canister line to fuel tank.(ii) Canister purge line.POSITIVE CRANKCASE VENTILATION INTAKEFILTERI. Pry the filter holder upwards to release it fromthe rocker cover.2. Discard the sponge filter.2. Loosen the clamp pinch bolt3. Remove the canister.fit new filter‘,,.3. insert a new filter into the plastic body.4. Push the filter holder onto the rocker coveruntil it clips firmly into place.: .:.:’Fit new canister4. Secure the canister in the clamp.5. Reverse instructions 1 and 2 above.WARNING: The use of compressed air to clean acharcoal canister or to clear a blockage in theevaporative system is highly dangerous. Anexplosive gas present in a fully saturated canistermay be ignited by the heat generated whencompressed air passes through the canister.J/‘,...16.:


MAINTENANCE 110 1CLEAN PLENUM CHAMBER VENTILATIONPASSAGEWAYThe cleaning of the plenum chamber ventilationpassageway can be carried out without removingthe plenum chamber from the ram housing.CAUTION: Care must be taken to prevent debrisfrom the passageway passing beyond the throttlevalve disc.WARNING: Safety glasses must be worn whenperforming this operation. Ensure that debris isnot blown into the atmosphere which could beharmful to other personnel within the vicinity.1.2.3.4.5.Disconnect the battery negative terminal.Release the hose clamp and remove the hosefrom the plenum chamber inlet neck.Remove the crankcase ventilation hose fromthe side of the plenum chamber.insert a piece of lint free cloth down thethrottle valve bore to prevent debris passingbeyond the throttle valve.Place a cloth over the tube protruding fromthe side of the plenum from which theventilation hose was removed to preventdebris from the passageway being blown intotheatmosphere.7. Any remaining consolidated matter can bedislodged using a piece of soft bent wire or apipe cleaner. Finally the passageway mustagain be blown out to remove any remainingdebris.8. Remove the small ‘T’ piece between thecrankcase ventilation hoses and check that it isfree from blockages, clean as necessary.9. Refit the IT’ piece and hoses, tighten the hoseclamps securely.CLEAN POSITIVE CRANKCASE VENTILATIONBREATHER FILTER1. Release the hose clamp and pull the hose offthe canister.2. Unscrew the canister and remove if from therocker cover.3. Remove the large ‘0’ ring from the threadedend of the canister.4. Visually inspect the condition of the wirescreen within the canister, if in poor conditionfit a new assembly, if in an acceptablecondition clean the screen as follows:NOTE: 1988 Model Year Vehicles - The ventilationpassageway has been modified and is now astraight through drilling into the throttle disc bore.Check and clean as stated in the recommendedmaintenance schedule.5. Immerse the canister insolvent and allow timedissolve and loosen anywithin the canister.a small amount offor the solvent toengine fume debris6. Remove canister from solvent bath and allowto dry out in still air.WARNING: Do not use a cohpressed air line toremove any remaining solvent or particles ofdebris within the canister as this could cause fireor personal injury.RR2177E6. Use a compressed air line with a slim bentnozzle to enable the passageway to becleaned out from within the throttle valvebore.Refitting the breather/filter7. Fit a new rubber ‘0’ ring.8. Screw the canister into the rocker cover, handtight only.9. Refit hose and tighten hose clamp securely.REVISED: SEPT. 90 1 7


MAINTENANCE1987-91 f;“o”v;GENERAL MAINTENANCE AND ADJUSTMENTSCHECK/ADJUST OPERATION OF ALL WASHERSAND TOP-UP RESERVOIR1. Check the operation of windscreen, tailgateand headlamp washers.2. Adjust jets if necessary by inserting a needleor very fine sharp implement into the jetorifice and maneuvring to alter the jetdirection.3. Unclip the reservoir cap.4. Top up reservoir to within 25mm (I in) belowthe bottom of the filler neck.Use a screen washer solvent/anti-freeze in thereservoir, this will assist in removing mud, fliesand road film and protect against freezing.CHECKCheck ignition wiring and high tension leads forfraying, chafing and deterioration.CHECKCheck/adjust ignition timing. (See Engine TuningData/Procedure) using suitable electronicequipment.FUEL SYSTEMCheck all hose connections for leaks and hosedeterioration, fit new hoses or tighten hoseclamps as necessary..: . .


R”d;;; 1987-91MAINTENANCE:.,IGNITION:.Spark plugs.1. Take great care when fitting spark plugs not tocross-thread the plug, otherwise costlydamage to the cylinder head will result.2. Check or replace the spark plugs as applicable.3. it is important that only the correct type ofspark plugs are used for replacements.4. Incorrect grades of plugs may lead to pistonoverheating and engine failure.,; .,,To remove spark plugs proceed as follows:..:,5. Disconnect the battery negative lead andremove the leads from the spark plugs.6. Remove the plugs and washers.RR1676E\+J+JDISTRIBUTOR-LUCAS 35DLM8._‘. :The electronic ignition employs a Lucas 35DLMBdistributor.The internal operating parts of the distributor arepre-set at the factory and should not normallyrequire resetting.Adjustments should only be made, if the unit isknown to be faulty or damaged. Maintenance ofthe distributor consists of the following items.: ;’‘. ,’”..,,:::.’.’,’7. Set the electrode gap to the recommendedclearance.8. When pushing the leads onto the plugs,ensure that the shrouds are firmly seated onthe plugs.Fitting H.T. leads9. Ensure that replacement H.T. leads are refittedin their spacing cleats in accordance with thecorrect layout illustrated.Failure to observe this instruction may result incross-firing between two closely fitted leadswhich are consecutive in the firing order.1. Clean outer surfaces of distributor cap toremove dirt, grease etc.2. Unclip the cap, check cap for signs ofcracking.3. Wipe inside cap with a lint free cloth.4. Check rotor arm, cap and flash shield for signsof tracking.5. Apply a spot of clean engine oil into the rotorspindle after the rotor arm has been removed.DO NOT DISTURB the clear plasticinsulating cover (flash shield) whichprotects the magnetic pick-up module.,. ‘,:..:,.,-‘,: 5,‘.REVISED: SEPT SO1 8


MAINTENANCE1987-91 ro;;;CHECK AIR CONDlTlONlNG SYSTEMWARNING: Adjustments or rectificationoperations should be carried out by a RangeRover dealer or a trained automotive airconditioning specialist. Under no circumstancesshould non-qualified personnel attempt repair orservicing of air conditioning equipment.The following items should be checked:1. Condenser: Clean the exterior of thecondenser matrix using a water hose orcompressed air-line.2.3.4.5.6.Check pipe connections for signs of fluidleakage.Evaporator: Examine the pipe connections forsigns of fluid leakage.Receiver/drier sight glass: After running theengine for five minutes with the airconditioning system in operation, examine thesight glass, there should be no sign ofbubbles.Check pipe connections for signs of fluidleakage.Compressor: Check the pipe connections forfluid leakage and the hoses for swellings.3. With a cold engine, the correct coolant levelshould be up to the ‘Water Level’ platesituated inside the expansion tank below thefiller neck.NOTE: The water level plate on later models hasbeen deleted from the expansion tank, thereforethe coolant should be filled to the top of thesensor float which is approximately 1.00 inch (25mm) below the filler neck.4. From 1990 model year, the expansion tankcoolant should be level with the top of theindicator post, visible inside the tank throughthe filler hole.CHECK/TOP UP COOLING SYSTEM1. To prevent corrosion of the aluminium alloyengine parts it is imperative that the coolingsystem is filled with a solution of water andphosphate free anti-freeze, winter or summer.Never fill or top up with plain water.WARNING: Do not remove the filler cap whenengine is hot because the cooling system ispressurized and personal scalding could result.2. When removing the filler cap, first turn itcounter-clockwise a quarter of a turn andallow all pressure to escape, before turningfurther in the same direction to lift it off.RR2974M5.6.If necessary, top up the cooling system withpremixed coolant. Use soft water wheneverpossible, if local water supply is hard,rainwater should be used.When replacing the filler cap it is importantthat it is tightened down fully. Failure totighten the filler cap properly may result inwater loss, with possible damage to theengine through over-heating.Check cooling/heater systems for leaks andhoses for security and condition.Cooling system hoses should be changed at thefirst signs of deterioration.The cooling system should be drained and flushedat 2 year intervals or at the onset of the secondwinter. Refer to Coolant Requirements in Section 26- Cooling System.2 0 REVISED: SEPT 90


:MAINTEr”“”Id3.:.:, .,IRRl?eQE1. Air conditioning compressor.2. Idler pulley3. Viscous fan-water pump unit.4. Idler pulley. 5. Crankshaft.6. Power steering pump.7. AlternatorWARNING: DISCONNECT THE BATTERY NEGATIVE TERMINAL BEFORE ADJUSTING DRIVE BELTS TOAVOID THE POSSIBILITY OF THE VEHICLE BEING STARTED.4‘.‘. ..x:..\y’>;y . . . . .,*, i..Y-.‘,, .:,_: ~.,.:.;‘:..:21.;:..: ..,


DRIVE BELTS-adjust or fit new belts ILLUSTRATION ACOMPRESSOR DRIVE BELTThe ljelt must be tight with not more than 4 to6mm (0.19 to 0.25 in) total deflection whenchecked by hand midway between the pulleys onthe longest run.Where a belt has stretched beyond the limits, anoisy whine or knock will often be evident duringoperating, if necessary adjust as follows:1.2.3.Loosen the idler pulley securing bolt.Adjust the position of the idler pulley until thecorrect tension is obtained.Tighten the securing bolt and recheck the belttension., 4mm_rC 6 m m ; m - - q - -. :-, _ .I-.-ILLUSTRATIONBCheck driving belts, adjust or fit new belts asnecessary.1. Examine the following belts for wear andcondition and fit new belts if necessary:(A) Crankshaft-idler pulley-Water Pump(6) Crankshaft-Steering Pump(C) Steering Pump-AlternatorILLUSTRATION C“,:Continued:“.’.’ .,‘.,. ::.:.: .’22 ..


MAINTENANCE ii0 1Each belt should be sufficiently tight to drivethe appropriate auxiliary without undue loadon the bearings.Loosen the bolts securing the unit to itsmounting bracket.Loosen the appropriate pivot bolt or idlerpulley and the fixing at the adjustment linkwhere applicable.Pivot the unit inwards or outwards asnecessary and adjust until the correct belttension is obtained.CAUTION: When tensioning the power steeringpump drive belt DO NOT use the pump casingas a point of leverage. Failure to comply mayresult in damage to the pump casing anddistortion to the seal face causing fluid leakage.6. Belt deflection should be approximately 4 to6mm (0.19 to 0.25 in) at the points denotedby the bold arrows.7. Tighten all unit adjusting bolts. Checkadjustment again.CAUTION: When fitting a new drive belt, tensionthe belt as described above. Reconnect thebattery and start and run the engine for 3 to 5minutes at fast idle, after which time the beltmust be re-checked, re-tension the belt ifnecessary.CHECK STEERING BALL IOINTSBall joints are lubricated for the normal life of balljoints during manufacture and require no furtherlubrication. This applies only if the rubber boot hasnot become dislodged or damaged. The jointsshould be checked at the specified mileage intervalsbut more frequently if the vehicle is used underarduous conditions.1. Check for wear in the joints by moving theball joint up and down vigorously. If freemovement is apparent fit a new jointassembly.Check/adjust front wheel alignmentUse recognised wheel alignment equipment toperform this check and adjustment. See ‘GeneralSpecification’ section for the correct alignment.To adjust1. Set the vehicle on level ground, with the roadwheels in the straight ahead position, andpush it forward a short distance.2. Loosen the clamps securing the adjusting shaftto the track rod.3. Turn the adjusting shaft to decrease orincrease the effective length of the track rod,as necessary, until the toe-out is correct.STEERING AND SUSPENSIONCheck condition and security of steering unit,joints, relays and boots.Check steering box for oil/fluid leaks.Check shock absorbers for fluid leaks.Check power steering system for leaks, hydraulicpipes and unions for chafing and corrosion.4. Retighten the clamps.5. Push the vehicle rear-wards, turning thesteering wheel from side JO side to settle theball joints. Then with the road wheels in thestraight ahead position, push the vehicleforward a short distance.6. Recheck the toe-out. If necessary carry outfurther adjustment.REVISED: MARCH 90 23


1987 KANGEROVERCONVERTER HOUSING WADING PLUGThe converter housing can be completelysealed to exclude mud and water under severewading conditions, by means of a plug fittedin the bottom of the housing.The plug is stored in the vehicle tool kit andshould only be fitted when the vehicle isexpected to do wading or very muddy work.When the plug is in use it must be removedperiodically to check for possible oil seepagedue to defective seals.CHECK ROAD SPRINGSVerify that the vehicle is being operated within thespecified maximum loading capabilities. Drive thevehicle onto level ground and remove all loads.Should the vehicle lean to one side it indicates afault with the springs or shock absorbers, not theself-levellinf: unit. If the levellina unit is believed tobe at fa>t, the procedure “below shouldfollowed:Check the levelling unit for excessiveleakage and if present the unit mustchanged. Slight oil seepage is permissible..* . . *Remove any excessrve mud deposlts and looseitems from the rear seat and load area.Measure the clearance between the rear axlebump pad and the bump stop rubber at thebeoilbefront outer corner of the bump pad on bothsides of the vehicle. The average clearanceshould be in excess of 67mm (2.8 in). If it isless than this figure remove the rear springsand check their free length against the ‘RoadSpring Data’. Replace any spring whose freelength is more than 20mm (0.78 in) shorterthan the figure given. If after replacing a springthe average bump clearance is still less than 67mm (2.8 in), replace the levelling unit...- .,\/Rm904E\,4. With the rear seat upright, load 450 kg (992lb) into the rear of the vehicle, distributing theload evenly over the floor area. Check thebump stop clearance, with the driving seatoccupied.5. Drive the vehicle for approximately 5 km (3miles) over undulating roads or graded tracks.Bring the vehicle to rest by light brakeapplication so as not to disturb the vehicleloading. With the driving seat occupied, checkthe bump stop clearance again.6. If the change in clearance is less than 20 mm(0.767 in) the levelling unit must be replaced.x,,, ‘12 4REVISED: MARCH 90


yg;; 1987MAINTENANCEBRAKESCheck visually, hydraulic pipes and unions forchafing, leaks and corrosion.Check/top up brake fluid reservoir - AP Typemaster cylinder and servo.The tandem brake reservoir is integral with theservo unit and master cylinder.Remove cap to check fluid level; top up ifnecessary until the fluid reaches the bottom ofthe filler neck. (See recommended Lubricants,Fluids and Capacities, Section 09). DO NOTOVERFILL.If significant topping up is required checkmaster cylinder, brake disc cylinders and brakepipes and connections for leakage; anyleakage must be rectified immediately.CHECK AND TOP UP BRAKE FLUID RESERVOIR-Lucas Girling master cylinder and servo1. Visually check the brake fluid level against the‘MIN’ and ‘MAX’ level markings on the side ofthe reservoir.2. If necessary top up with the recommendedgrade of fluid (refer to section 09 lubricants,fluids and capacities). DO NOT OVERFILL.3. Release the cap with combined fluid levelswitch by rotating counter- clockwise.Withdraw the cap and switch, top up thereservoir.CAUTION : When topping up the reservoir careshould be taken to ensure that the brake fluiddoes not come into contact with any of thevehicle paintwork. Should this occur, wash theaffected area IMMEDIATELY with a large quantityof water.CAUTION : When topping up the reservoir careshould be taken to ensure that the brake fluiddoes not come into contact with any of thevehicle paintwork. Should this occur, wash theaffected area IMMEDIATELY with a large quantityof water.ContinuedREVISED: DEC. 87 25: :


-l 10 MAINTENANCEADJUST PARKING BRAKEThe parking brake lever acts on a brake drum at therear of the transfer box.1. Set the vehicle on level ground and select ‘P’in main gearbox. Disconnect the batterynegative lead.2. Fully release the parking brake.3. From underneath the vehicle loosen the twolocknuts securing the parking brake outercable to the mounting bracket, to enable thebrake drum to be adjusted without putting anytension on the parking brake outer cable.CAUTION: DO NOT overadjust the parkingbrake, the drum must be free to rotate when theparking brake is released, otherwise seriousdamage will result.CHECK SERVICE BRAKE OPERATIONIf the service brake pedal is ‘spongy’ bleed thebrake system (refer to Brakes - section 70). Checkall hoses and pipes for security, fractures and leaks.Fit new hoses and pipes as necessary.FRONT AND REAR BRAKE PADS (Service Brakes)Brake pad wear is indicated by a pad wear warninglight incorporated in the instrument binnacle. Thewarning lamp is illuminated when pad wear isreduced to approximately 3.0mm (0.118 in). Thesystem is operated by an electrical sensorincorporated into both the front right and rear lefthand side inboard brake pads, on early models.Later models have the rear pad wear sensor locatedin the inboard pad of the rear right hand caliper.When pad wear is sufficient in either front or rearpads the sensor within the pads will complete acircuit to ground through the disc, thus illuminatingthe warning lamp in the instrument binnacle.Brake pad identification4. Rotate the adjuster on the brake drum backplate clockwise, until the brake shoes are fullyexpanded against the drum.From the side of the vehicle, looking through thedisc and caliper at the inboard pad, the ‘D’ shapedmaterial on the rear of the inboard pad should facethe direction of forward rotation of the road wheelso that the curved part of the ‘D’ is always at thetrailing end of the caliper.Brake pad wear sensed at left rear wheel,--./’ *l c-.‘\ 1’ , ‘r‘,\ ,/‘\;...i;‘: :‘\ ,’0 0 ‘-”::::;: ‘:;,;:5. Rotate the two outer cable locknuts untilcontact is made with the mounting bracket,tighten the two nuts consecutively to preventany movement occurring on the outer cable.6. Loosen the adjuster on the back of the brakedrum until the parking brake lever becomesfully operational on the second or third notchof the parking brake ratchet,7. Lightly grease the parking brake linkage with ageneral purpose grease.0 0”>>RR 2356M ----!--Direction of rotation. . . . .:‘j.,.t :’..‘.: 1.‘. ,(‘.l. ‘. .,.::,. :::,::‘.Z.26 _ REVISED: DEC. 87‘..‘.’


PO;;; 1987MAINTENANCEBrake pad wear sensed at right rear wheel8. Clean the exposed parts of the pistons, usingnew brake fluid.9. Using piston clamp 18G672 press each pistonback into its bore, while ensuring that thedisplaced brake fluid does not overflow fromthe reservoir.Fit new front brake padsDirection of rotationNOTE: Ensure ‘P’ is selected in maingearbox, differential lock is engaged andthat the parking brake is applied.1. Loosen the wheel nuts on both front wheels,raise the front of the vehicle and lower ontoaxle stands, and remove the front road wheels.2. Disconnect the battery negative terminal.3. Disconnect the two-pin electrical plug at therear of the disc mudshield (front right handside only).4. Clean the exterior of the calipers.5. Remove the cotter pins from the brake caliper.6. Remove the retaining springs.7. Withdraw the brake pads.RR666M10. Coat the faces of the pistons with Lockheeddisc brake lubricant taking care not to let anyreach the lining material.11. Insert the new brake pads.12. Place the brake pad retaining springs inposition, fit new cotter pins and spread theends.13. Apply the service brake pedal several times tolocate the pads.14. Check the fluid reservoir and top up ifnecessary.15. Fit the road wheels, and secure them inposition with the wheel nuts, do not fullytighten the wheel nuts at this stage, lower thevehicle and finally tighten the wheel nuts tothe specified torque value.Fit new rear brake padsJacking up the rear of the vehicle, follow theprocedure as for front pads.1. Early vehicles - The two-pin electrical plug forrear brake pad wear indication is located onthe left hand rear caliper inboard pad.later vehicles - The two pin electrical plug forrear brake pad wear indication is located onthe right hand rear caliper Jnboard pad.CHECK BRAKE SERVO HOSE(S)Visually inspect all servo hoses and connections forcondition and security.REVISED: DEC. 87 27


MAINTENANCE1987 r(ANbtROVERBRAKE FLUIDBrake fluid absorbs water and in time the boilingpoint of the fluid will be lowered sufficiently tocause the fluid to be vapourised by the heatgenerated when the vehicle brakes are applied.This will result in loss of braking efficiency or inextreme cases brake failure.Therefore, all fluid in the brake system should bechanged at the service intervals quoted in therecommended maintenance schedules.Fluid should also be changed before touring inmountainous areas if not changed in the previousnine months.Care must be taken always to observe the followingpoints:. .(a) At all times use the recommended brake fluid.tb) Never leave fluid in unsealed containers as itabsorbs moisture quickly and can bedangerous if used in the braking system in thiscondition.fc) Fluid drained from the system or used forbleeding should be discarded.(d) The necessity for absolute cleanlinessthroughout cannot be over emphasised.BATTERYWARNING: Hydrogen and oxygen gases areproduced during normal battery operation. Thisgas mixture can explode if flames, sparks orlighted tobacco are brought near the battery.When charging or using a battery in an enclosedspace, always provide ventilation and shield youreyes.Keep out of reach of children. Batteries containsulphuric acid. Avoid contact with skin, eyes, orclothing. Also, shield your eyes when workingnear the battery to protect against possiblesplashing of the acid solution. In case of acidcontact with skin, eyes, or clothing, flushimmediately with water for a minimum of fifteenminutes. If acid is swallowed, drink largequantities of milk or water, followed by milk ofmagnesia, a beaten egg, or vegetable oil.SEEK MEDICAL AID IMMEDIATELY.A low maintenance battery is installed in thevehicle. Dependent upon climate conditions theelectrolyte levels should be checked as follows:Temperate climates every three years.Hot climates every year.The exterior of the battery should be occasionallywiped clean to remove any dirt or grease.Periodically remove the battery terminals to cleanand coat with petroleum jelly.NOTE: If a new battery is fitted to the vehicle itshould be the same type as fitted to the vehiclewhen new. Alternative batteries may vary in sizeand terminal positions and this could be apossible fire hazard if the terminals or leadscome into contact with the battery clampassembly. When fitting a new battery ensure thatthe terminals and leads are clear of the batteryclamp assembly.28REVISED: DEC. 87 :A,..


MAINTENANCE 110 iRESET EMISSION MAINTENANCE REMINDERThe emission maintenance reminder is designed toactivate at 52,500 and 105,000 miles respectivelyand will illuminate a ‘Check Engine’ red warninglight in the auxiliary switch panel.The control unit is located behind the lower dashpanel and is attached to the side of the steeringcolumn support bracket above the relays. Access tothe unit is gained by removing the lower dashpanel.The control unit colour is brown, mounted on abrown plug, ‘EMISSION MAINTENANCE REMINDER’is embossed in white on the side of the unit. Atamper-proof label is attached to the top of the unit.The emission maintenance reminder must be resetafter the required maintenance has been carried outand a new tamperproof label fitted by a RangeRover of North America dealer. This Emissionmaintenance reminder is part of the EmissionControl System, refer to section 17.The unit can be reset as follows:4. Using a small thin metallic probe, place theprobe into the access hole and momentarilyelectrically short between the reset pins withinthe unit.5. Refit the control unit to the plug, switch onthe ignition, the ‘CHECK ENGINE’ wiiminglight in the auxiliary switch panel will initiallylight up as part of the unit’s inbuilt checkfeature, if the unit has been reset correctly thewarning light will go out after a few seconds.Should the warning light remain illuminated,repeat the resetting procedure.6. Fit a new tamperproof label.7. Endorse the Passport to service.EMISSION MAINTENANCE REMINDER- 1989 MODEL YEARThe mileage intervals for 88 Model year also applyto 89 Model year.The control unit is now located under the rear ofthe right hand front seat.3f6 -‘\ I / //-.’1. Remove the fixings and lower the lower dashpanel.2. Identify the control unit and remove it fromthe plug.3. Remove the tamperproof label to reveal theaccess hole for resetting.RR2552E-Follow instructions 2. to 7. to reset the unit.REVISED: SEPT. 88 29


I i 0 IMAINTENANCE1989 k”d;;;ADJUST PARKING BRAKESet the vehicle on level ground and select 'PIin automatic gearbox or neutral in manualgearbox. Disconnect the battery negativeterminal.Chock the road wheels.Fully release the parking brake lever.From underneath the vehicle, rotate theadjuster on the brake drum back plateclockwise until the brake shoes are fullyexpanded against the brake drum.8.9.10.Operate the parkbrake once or twice to settlethe brake shoes, recheck that the parkbrake isfully operational on the third notch of theratchet. Readjust as necessary.Refit the glove box liner.Reconnect the battery and remove the wheelchocks.5. Back off the adjuster until the drum is free torotate.6. Release the four screws and remove the glovebox liner.7. Rotate the adjustment thumbwheel below theparkbrake lever until the parkbrake is fullyoperational on the third notch of the ratchet.NOTE: The parking brake adjustmentthumbwheel must only be used for initialsetting and to compensate for cable stretch,it must not be used to take up brake shoewear, which must continue to be adjustedat the brake drum.ADDITION: SEPT. 88


$E; 1989MAINTENANCE,,,TOP UP TRANSFER GEARBOX OIL- Borg Warner gearboxRENEW TRANSFER GEARBOX OIL- Borg Warner gearboxNOTE: The existing maintenance intervals for theLT230 are also applicable to the Borg Warnertransfer gearbox.NOTE: The existing maintenance intervals for theLT230 are also applicable to the Borg Warnertransfer gearbox./1. Before topping up the oil ensure that thevehicle is level, either on a hoist or on theground.2. Disconnect the battery negative terminal.3. Clean the immediate area around thefiller/level plug.4. Remove the plug and fill the gearbox with therecommended grade of oil, until oil starts toseep from the filler/level hole.5. Clean any previously applied sealant from thefiller/level plug.6. Apply Hylomar sealant to the threads of theplug and refit the plug. Tighten to thespecifiedtorque.1. Before renewing the oil ensure that the vehicleis level, either on a hoist or on the ground.2. Disconnect the battery negative terminal.3. Clean the immediate area around thefiller/level and drain plugs.WARNING: When draining the gearbox careshould be taken to ensure that the oil isnot hot as personal scalding could result.4. Place a container under the gearbox to drainthe oil into.5. Remove the filler/level plug to vent thegearbox and assist draining.6. Remove the drain plug and allow the oil todrain.1“ 2h‘. ’.7. Wipe away any surplus oil.8. Reconnect the battery.7. Thoroughly clean the drain plug threads priorto applying fresh ‘Hylomar’ sealant. Fit andtighten the plug to the specified torque.8. Fill the gearbox with the correct quantity andgrade of oil until oil seeps from the filler levelhole. Wipe away any surplus oil.9. Thoroughly clean the filler/level plug threadsprior to applying fresh ‘Hylomar’ sealant. Fitand tighten the plug to thd specified torque.10. Reconnect the battery.;:!._ .’. .:‘. .,:.” ,’ “’,.,. .‘,‘,.,., . .ADDITION: SEPT. BE/REVISED: SEPT. 90 31


:‘..’: ,.. ,, :i., : ,’:,I:: ‘.>’Charcoal canister DYNAMOMETER TESTING OF PERMANENT FOURWHEEL DRIVE VEHICLESRemove and refit1. Disconnect battery negative lead.2. Disconnect both purge lines.3. Release canister from its mounting braket.NOTE: THIS INFORMATION APPLIES TOVEHICLES FllTED WITH BORG WARNERTRANSFER GEARBOX WITH VISCOUS COUPLINGThese vehicles are identified by the absence of thediff-lock position on the transfer gearbox lever.ViscouscouplingThe front and rear axles cannot be drivenindependently due to the viscous coupling. Thiseliminates the need for the differential lock byprogressively locking the centre differentialautomatically if any slip occurs at any wheel.WARNING: DO NOT attempt to drive individualwheels with the vehicle supported on floor jacksor stands.Four wheel dynamometersProvided that the front and rear dynamometerrollers are rotating at identical speeds and thatnormal workshop safety standards are applied, thereis no speed restriction during testing except for anythat may apply to the tyres.,:‘..;A ‘:‘. .,c’: .’::.:’:r,:...,.,.:, :Refitting4. Reverse the removal procedure, ensuring thatthe canister is securely located in its mountingbracket and both purge lines are fittedcorrectly to the canister.Two wheel dynamometersIMPORTANT: Use a four wheel dynamometer forbrake testing if possible.If brake testing on a single axle rig is necessary itmust be carried out with the drive shaft to the rearaxle removed, AND neutral selected in BOTH maingearbox and transfer gearbox. When checkingbrakes, run engine at idle speed to maintain servovacuum.If checking engine performance, the transfer boxmust be in high range and the drive shaft to thestationary axle must be removed.TOWINGNote the towing procedure (Section 10, page 7) forprevious models applies to vehicles fitted with BorgWarner transfer gearbox. The main gearbox andtransfer gearbox must be in neutr aIwhen thevehicle is being towed.\i32 .ADDITION: SEPT. 88


MAINTENANCE 110 1DYNAMOMETER TESTING OF PERMANENT FOURWHEEL DRIVE VEHICLESNOTE: THIS INFORMATION APPLIES TOVEHICLES FllTED WITH ANTI-LOCK BRAKESYSTEMWARNING: DO NOT ATTEMPT TO TEST ABSFUNCTION ON A DYNAMOMETERFour wheel dynamometersNOTE: Before testing the vehicle on a four wheeldynamometer disconnect the valve relay - seeSection 70 Brakes, page 54. The ABS function willnot work, the ABS warning light will illuminate.Normal braking will be available.ABS BRAKE FLUID RESERVOIRCheck/top up fluid level1. Park the vehicle on level ground.2. Turn ignition ON, to activate hydraulic pump.If pump does not activate depress brake pedalseveral times until it is heard to operate.3. When the pump stops, check that the level isbetween the ‘MINI and ‘MAX’ marks.4. If the level is below the ‘MINI mark onreservoir, using the correct fluid, - see Section09, Lubricants and Fluids.WARNING: Clean reservoir body and filler capbefore removing the cap. Use only fluid from asealedcontainer.Provided that the front and rear rollers are rotatingat identical speeds and that normal workshop safetystandards are applied, there is no speed restrictionduring testing except for any that may apply to thetyres.Two wheel dynamometersIMPORTANT: Use a four wheel dynamometer forbrake testing if possible.NOTE: ABS will not function on a two wheeldynamometer. The ABS light will illuminateduring testing. Normal braking will be available.If brake testing on a single rig is necessary it mustbe carried out with the drive shaft to the rear axleremoved, AND neutral selected in BOTH maingearbox and transfer gearbox.If checking engine performance, the transfer boxmust be in high range and the drive shaft to thestationary axle must be removed.ADDITION: SEPT. BSIREVISED: SEPT. 90 33.:...


,,.,‘:‘,.MAINTENANCE1990 KANLetROVER‘.‘. ”,’FUEL FILTER - 1991 MODEL YEARRemove and refit\WARNING: Ensure that the fuel handlingprecautions given in Section 01 - Introductionregarding fuel handling are strictly adhered towhen carrying out the following instructions.WARNING: The spilling of fuel is unavoidableduring this operation. Ensure that all necessaryprecautions are taken to prevent fire andexplosion.Removing1. Depressurise the fuel system.2. The fuel filter is located on the right-handchassis side member forward of the fuel tankfiller neck. Access to the filter is gainedthrough the right-hand rear wheel arch.3. Clamp the inlet and outlet hoses to preventthe minimum of fuel spillage whendisconnecting the hoses.4. Loosen the two fuel unions and remove thehoses from the filter canister.5. Release the single nut and bolt securing thefilter and clamp and remove the filter.,- -’ - .--..-.-.- .~.-- -- .-_._RR2966ERefitting6. Fit a new filter observing the direction of flowarrow on the canister.7. Tighten the single nut and bolt.8. Fit the inlet and outlet hoses. Tighten theunions to a torque of 20-25 ft lb(27-34Nm).9. Refit the fuel pump relay. Reconnect thebattery and recode the radio.10. Start the engine and inspect for fuel leaksaround the hose connections.:‘,:n .‘!.‘_ .,34 ADDITION: SEPT. 90


,.‘.:.ENGINEREMOVAL OF THE ENGINE FROM THE VEHICLEI. Prop the hood open, disconnect the screenwasher hose from the reservoir and electricalleads to the engine compartment illumination6.7.8.9.10.11.12.lamp. Remove the fixings, hinges to hood andlift the hood clear.Set the vehicle on level ground and apply thetransmission brake.De-pressurize the fuel system. (See FuelInjection System, Section 19).Disconnect the battery terminals and removethe battery from the vehicle.Release the hose clamp and remove theradiator bottom hose to enable the coolingsystem to be drained.Release the hose clamps and remove theradiator top hose and expansion tank hose.Remove the fan cowl, drive belt and viscousunit/fan assembly.Release the fixings and remove the radiator.Place an absorbent cloth around the fuel feedhose at the fuel rail and release thecompression nut, remove the feed hose fromthe rail, seal the end of the pipes with maskingtape to prevent ingress of dirt.Release the hose clamp and remove the fuelreturn hose from the pressure regulator, sealboth openings with masking tape to preventingress of dirt. Remove the vacuum hose fromthe rear of the regulator.Detach the throttle lever return springs,remove the fixings securing the kickdowncable anchor bracket to the plenum chamberbracketry and lay the assembly to one side.DO NOT DISTURB THE KICK DOWN CABLESETTING.Disconnect the multi-plug from the air bypassvalve (stepper motor).13.14.15.16.17.18.19.20.Release the hose clamp securing the hose tothe inlet neck of the plenum chamber.Disconnect the multi-plug from the air flowsensor, release the two clips securing the aircleaner to the air flow sensor, remove thesensor complete with hose from the enginecompartment.Release the fixings and remove the air cleanerassembly from the engine compartment.Release the alternator pivot bolts and removethe drive belt, remove the alternator fixingsand withdraw the alternator.Release the idler pulley between the crankshaftpulley and compressor pulley and remove thedrive belt.Release the compressor from its mounting andlay to one side. DO NOT discharge the airconditioningsystem.NOTE: Release the bolts securing thecompressor mounting bracket to the engineand remove the bracket to enable atemporary lifting eye ETC 5964 to be fitted.Secure the lifting eye to the mountingbracket fixing points with suitable bolts ofequivalent size, pitch and thread. Leave thelifting eye attached to the engine until theengine has been reinstalled in the vehicle.Place a drain tray underneath the vehicle tocatch any power steering fluid which may seepfrom the steering fluid reservoir when thehose is disconnected from the steering pump.Disconnect the hose and secure the end of itabove the level of the fluid reservoir to avoidthe loss of any more fluid than necessary. Sealthe power steering pump and pipe openingwith masking tape to prevent ingress of dirt.Continued'- . .., '_,;' ,' 'y?.,1


1987 MNbtROVER‘_‘. ,21.27.20.29.30.31.32.33.34.Disconnect the power steering pump topower steering box hose, seal the hose andpump opening with masking tape to preventingress of dirt. Wipe away any fluid that mayhave come into contact with the chassis orsteering box.Remove the two coolant hoses and onecrankcase breather hose from thepotentiometer side of the plenum chamber.Disconnect the potentiometer multi-plug.Remove the distributor vacuum hose from thetop of the plenum chamber and disconnectthe vacuum supply hose to the cruise controlactuator.Remove the six bolts and maneuver theplenum chamber off the ram housing.Disconnect the hoses from around the outsideof the ram housing and remove the six boltssecuring the ram housing to the intakemanifold.Lift the ram housing clear of the intakemanifold and remove it from the enginecompartment. Place a protective cover overthe intake manifold openings to preventingress of dirt.Disconnect the fuel temperature and coolanttemperature sensor multi-plugs.Disconnect the High tension and Low tensionleads from the coil.Identify each injector multi-plug forre-assembly and disconnect the plugs from theinjectors.Maneuver the harnesses from behind the fuelrails and place aside , clear of the engineassembly.Remove the two clamps securing theautomatic gearbox oil cooler pipes to thebottom left hand side of the engine block.Remove the top and bottom nuts securing theengine mountings at either side of the cylinderblock.Fit suitable lifting chains to the engine liftingeyes located at the front of both cylinderheads and the rear of the right hand cylinderhead.(See illustration for recommended chainlengths).KEY TO CHAIN LENGTHS35.36.37.38.39.40.L/H Front chain 356min(14 in.) total overall length.R/H Front chain 330mm(13 in.) total overall length.R/H Rear chain 457mm(18 in.) total overall length.NOTE: All chain dimensions are measuredfrom the end of the lifting hook to the endof the last link in the chain.Fit the chain lifting eye to a suitable hydraulichoist. Raise the hoist sufficiently high enoughto enable the engine mounting rubbers to beremoved, and withdraw the rubber mountings.Lower the hoist until the engine rests securelyon the engine mounting brackets. Remove thelifting chains and hoist.Disconnect the two heater hoses located onthe top of the right hand rocker cover.Remove the ground strap from the rear of theleft hand cylinder head.Remove the cylinder block to hood groundstrap from the retaining clip at the enginecompartment closure panel.Remove all electrical harnesses from theretaining clips on and around the rear of theengine.-.2,.:, ‘, :,


’‘,..:’:.‘.‘_:.:., ::41.42.43.44.45.46.47.40.49.50.Remove the gearbox breather pipe from theretaining clip at the rear right hand lifting eye.Remove the top two bolts securing the bellhousing to cylinder block.Position a suitable hydraulic floor jack underthe front differential casing, raise the front ofthe vehicle sufficiently to enable two axlestands to be positioned under the front axle,lower the vehicle on to the axle stands.Remove the bolts securing the bell housingbottom cover, detach the cover from the bellhousing and remove the gasket from the bellhousing face.Remove the transfer box to engine block tiebar.Remove the nuts securing the exhaustdownpipes to the manifolds, remove the heatshield from the right hand side downpipe.Remove the electrical leads from the rear ofthe starter motor solenoid, and disconnect themulti-plug from the oil level sensor on theside of the sump.With the assistance of a second person torotate the engine at the crankshaft pulley,rotate the crankshaft until two of the accessholes in the drive plate/ring gear assembly arevisible through the bellhousing bottom coveropening.Remove the two bolts that are visible throughthe access holes, which secure the flexibledrive plate to the torque converter. Mark oneof the access holes and one of the bolt holeswith some means of identification to enablethe unit to be fitted in the same position onre-assembly to maintain the original buildsetting.Rotate the crankshaft 180” until the tworemaining access holes are visible, and removethe two bolts.RRl8OBE51.52.53.54.55.56.57.58.Remove the remaining bell housing to cylinderblock bolts.Raise the vehicle off the axle stands using asuitable hydraulic floor jack under the frontaxle, remove the stands and lower the vehicleto rest on its road wheels.Fit the engine lifting eyes, locate the chainlifting eye into the floor crane.Remove the starter motor ground strap fromthe chassis.Place a hydraulic floor jack under the gearboxbell housing to support the gearbox when theengine and gearbox are separated.Carefully raise the crane a little, ease theengine to gearbox joint faces apart, steady theengine on the crane.Ensure there are no restricting electricalharnesses, hoses, pipes, or components thatwill prevent the engine being raised clear ofthe engine compartment.Slowly-raise the engine clear of the enginecompartment, move the engine away fromvehicle and place on a suitable engine stand.FllTlNG THE ENGINE TO THE VEHICLE59. Fit the lifting chains to the lifting eyes on theengine as previously described in the removalprocedure.60. Raise the engine on a floor crane and lower itinto the engine compartment, ensuring that allharnesses, hoses, pipes and components areclear of the engine assembly.Continued3REVISED: jUNE 87 3., ,.‘,.


61. With assistance, maneuver the engine until thebottom two engine bolt holes align with theappropriate two holes in the bell housing. Fitthe two bolts and partially tighten. Ensure that:he two cylinder block dowels locate in theirrespective holes in the bell housing.62. Remove the hydraulic floor jack and lower thehoist until the engine rests securely on theengine mounting brackets.63. Fit the top two bell housing to engine cylinderblock securing bolts. Tighten to the specifiedtorque (see section OC-Torque values).64. Fit the remaining bell housing to cylinderblock bolts, and tighten to the specified65.66.67.torque (including the two bottom bolts).(seesection 06.Torque values).With assistance from a second person torotate the crankshaft pulley, line up thepreviously marked drive plate access hole withthe respective bolt hole in the torqueconverter. Fit the two bolts and tighten to thespecified torque (see section 06-Torquevalues).Rotate the crankshaft 180” and fit theremaining two bolts to the flexible drive plate,tighten to the specified torque (see sectionOC-Torque values).Fit new gasket and refit the bottom cover,tighten the bolts to the specified torque (seesection OCTorque values).68. Fit new exhaust flange gaskets, fit the exhaustto the manifold.69. Refit all harnesses, ground straps breatherpipes and hoses to their correct locations atthe rear of the engine.70. Raise the engine and refit the enginemounting rubbers, tighten the nuts to thespecified torque (see section 06-Torquevalues).71. Remove the temporary lifting eye ETC 5964and reverse the instructions 1 to 32, ensuringthat all electrical plugs and harnesses are fittedto their correct locations.DISMANTLE AND OVERHAUL THE ENGINERemove the engine from the vehicle and clean theexterior. In the interests of safety and efficientworking secure the engine to an approved enginestand. Drain the sump oil into a suitable container.Special tools:R0605351 - Guide bolts186537 - Torque wrench18G1150 - Piston pin remover/replacer - Basictool18G1150E - Adaptor remover/replacer - pistonpin16C106A - Spring compressorR0600959 - Drift - Valve guide replacement -intake and exhaustMS76 - Valve cutter handle setMS621- Valve seat cutterR0605774A - Distance piece for valve guideR0274401A - Drift for guide removal - intakeand exhaustR01014 - Crankshaft rear seal sleeveREMOVE THE INTAKE MANIFOLDRelease the hose clamp securing the hose tothe rear of the water pimpDetach the retaining clips from the top of theinjectors.Remove the four bolts securing the fuel rail tothe manifold.Withdraw the fuel rail and injectors.. .4 REVISED: JUNE 87:..,..


6.7.8.Evenly loosen and remove the twelve boltssecuring the intake manifold to the cylinderheads.Lift the intake manifold from the cylinderheads.Wipe away any surplus coolant lying on themanifold gasket and remove the gasket clampbolts and remove the clamps.Lift off the gasket and seals.1. Bend back the lock tabs, and remove the eightbolts securing each manifold, and withdrawthe manifolds and gaskets.;- .:, :.Remove exhaust manifoldsREMOVE AND OVERHAUL ROCKER SHAFTS ANDVALVE1.2.GEARRemove the spark plug leads from the sparkplugs and retaining clips, release the fourscrews and lift off the rocker covers.Remove the four rocker shaft retaining boltsand lift off the assembly.Withdraw the pushrods and retain in thesequence removed.Remove the hydraulic tappets and place toone side with their respective pushrods. If atappet cannot be removed leave in positionuntil the camshaft is removed.Remove water pump1. Remove the fifteen bolts and withdraw thewater pump and joint washer.NOTE: The water pump is not a serviceableitem, in the event of bearing failure orsevere corrosion to the pump impellervanes, fit a new water pump assembly.Continued’REVISED: SEPT. 90 5


-l 12 ENGINEDismantle rocker shafts 17.5.6.7.8.9.10.11.12,Remove the cotter pin from one end of therocker shaft.Withdraw the following components andretain them in the correct sequence forre-assembly:A plain washer.A wave washer.Rocker arms.Brackets.Springs.Examine each component for wear, inparticular the rockers and shafts. Discard weakor broken springs.18Tappets MUST rotate and a circular wearcondition is normal. Tappets with this wearpattern can be refitted provided there are noother defects.In the case of a non-rotating tappet, fit a newreplacement and check camshaft lobes forwear; also ensure the new tappet rotates freelyin the cylinder block.BT767MInspect tappets and pushrods13. Hydraulic tappet; inspect inner and outersurfaces of the body for blow holes andscoring. Replace hydraulic tappet if body isroughly scored or grooved, or has a blow holeextending through the wail in a position topermit oil leakage from the lower chamber.14. The prominent wear pattern just above thelower end of the body should not beconsidered a defect unless it is definitelygrooved or scored. It is caused by side thrustof the cam against the body while the tappetis moving vertically in its bore.15. Inspect the cam contact surface of thetappets. Fit new tappets if the surface isexcessively worn or damaged.16.A hydraulic tappet body that has been rotatingwill have a round wear pattern and anon-rotating tappet body will have a squarewear pattern with a very slight depression nearthe centre.19. Fit a new hydraulic tappet if the area wherethe pushrod contacts is rough or otherwisedamaged.20. Fit a new pushrod if it is bent or has a roughor damaged ball end or seat.Assemble rocker shafts21. Both shafts must be assembled so that theidentification groove is at the one o’clockposition with the push rod end of the rockersto the right.CAUTION: If the shafts and rockers areincorrectly assembled and fitted to the engine,the oil supply to the rocker shafts will berestricted.6 REVISED: SEPT. 90;:. (_


‘,22. Fit a cotter pin to one end of the rocker shaft.23. Slide a plain washer over the long end of theshaft to contact the cotter pin.24. Fit a wave washer to contact the plain washer.REMOVE AND OVERHAUL THE CYLINDER HEADSEvenly loosen the fourteen cylinder head boltsreversing the tightening order.Before removing the heads mark them relativeto the LH and RH side of the engine.Lift off the cylinder heads and discard thegasket.RR2937Mlm..;.’25.26.27.Early type rocker arms are angled. They mustbe fitted so that the valve end of the rockerarms angle away from each other as shown.On later type rocker arms the valve end isoffset and must be fitted as shown.Early and late types of rocker armsinterchangeable provided the complete set ischanged.Dismantle cylinder heads4.5Remove the spark plugs.Using the valve spring compressor 1% 106Aor a suitable alternative, remove the valves,springs and umbrella seals, retain them insequence for refitting. Discard the umbrellaseals fitted to the inlet valves only.RR2899M28. Assemble the rocker arms, brackets andsprings to the rocker shaft.29. Compress the springs, brackets and rockers,and fit a wave washer, plain washer and cotterpin to the end of the rocker shaft.30. Fit the locating bolts through the brackets andplace the assemblies to one side.Continued 4REVISED: SEPT. 90 7


I12 ENGINE1987 KnNbtROVER6. Clean the combustion chambers with a softwire brush.7. Clean the valves.8. Clean the valve guide bores.6 7 w wFit new valve guidesRegrind or fit new valves as necessary.If a valve must be ground to a knife-edge toobtain a true seat, fit a new valve.The correct angle for the valve seating face is45 degrees -t 114.The correct angle for the seat is 462 l/4degrees and the seat witness should betowards the outer edge.11w/4514.A.B.C.NOTE: Service valve guides are 0.025 mm(0.001 in) larger on the outside diameterthan the original equipment to ensureinterferencefit.Lubricate the new valve guide and place inposition.Using guide drift R0600959 partially drive theguide into the cyli,rder head.Remove the drift R0600959 and place distancepiece R0605774A over the valve guide,continue to drift the guide into the cylinderuntil drift contacts the distance piece.Alternatively drift the guide into the cylinderhead until it protrudes 19 mm (314 in) abovethe valve spring recess in the head.13. Check the valve guides and fit replacements asnecessary. Using the valve guide remover274401, drive out the old guides from thevalve spring seat face of the cylinder head.RR2355MExamine and fit new valve seats15. Check the valve seats for wear, pits andburning and fit new inserts if necessary.;..’ .m\,.’8 REVISED: SEPT. 90


1.Fog; 1987ENGINE 12 r-l.,:: .’16.17.18.Remove the old seat inserts by grinding themaway until they are thin enough to be crackedand pried out.Heat the cylinder head evenly toapproximately 65°C (150°F).Press the new insert into the recess in thecylinder head.NOTE: Service valve seat inserts areavailable in two over-sizes 0.25 and 0.50mm (0.010 and 0.020 in) larger on theoutside diameter to ensure interference fit.22. Ensure that the cutter blades are correctlyfitted to the cutter head with the angled endof the blade downwards facing the work, asillustrated.Check that the cutter blades are adjusted sothat the middle of the blade contacts the areaof material to be cut. Use the key provided inthe hand set MS76. Use light pressure andremove only the minimum material necessary.19.20.21.Using service tool MS621 if necessary, cut thevalve seats to 46+ l/4 degrees.The nominal seat width is 1.5 mm (0.059 in). Ifthe seat exceeds 2.0 mm (0.078 in) it shouldbe reduced to the specified width by the useof 20” and 70” cutters.The inlet valve seat diameter: ‘A’ is 37.03 mm(1.458 in) and the exhaust valve seat is 31.50mm (1.240).ST1 024M23.Coat the valve seat with a small quantity of‘engineers’ blue, revolve a properly groundvalve against the seat. A continuous fine lineshould appear round the valve. If there is agap of not more than 12 mm it can becorrected by lapping.24. Alternatively, insert a strip of cellophanebetween the valve and seat, hold the valvedown by the stem and slowly pull out thecellophane. If there is a drag the seal issatisfactory in that spot. Repeat this in at leasteight places. Lapping-in will correct a smallopen spot.Continued. ..,,.,.:;REVISED: JUNE 87 9,’.,.,,:,


I,987 KANGtROVERRemAssemble valves to cylinder head25. Before fitting the valves and springs the heightof each valve above the head must bechecked. Insert each valve in turn in its guideand while holding the head firmly against theseat, measure the height of the stem abovethe valve spring seat surface. This dimensionmust not exceed 47.63 mm (1.875 in). Ifnecessary fit a new valve or grind the end ofthe valve stem.26. Lubricate the valve stems and assemble thevalves, fit new umbrella seals and springs, fitthe caps, compress the springs and caps usingspring compressor 18G 106A and secure thesprings in place with the collets. Note that theumbrella seals are only fitted to the inletvalves.Holes 6 - These eight holes may be drilled 0.3906in dia. x 0.812 + 0.040 in deep. Tapped withHelicoil Tap No. 6 CBB 0.749 in (min) deep (318UNC 1.5D insert).Holes C - These four holes may be drilled 0.3906 india x 0.937 + 0.040 in deep. Tapped with HelicoilTap No. 6 CPB or 6CS x 0.875 in fmin) deep (318UNC 1.5D insert).Holes D - These four holes may be drilled 0.261 india x 0.675 + 0.040 in deep. Tapped with HelicoilTap No. 4 CPB or 4CS x 0.625 in (min) deep (l/4UNC 1.5D insert).Holes E - These six holes may be drilled 0.3906 india x 0.937 + 0.040 in deep. Tapped with HelicoilTap No. 6 CPB or 6CS x 0.875 in (min) deep (318UNC 1.5D insert). -..xReclaiming cylinder head threadsDamaged or stripped threads in the cylinder headcan be salvaged by fitting Helicoils as follows:Holes A - These three holes may be drilled 0.3906in dia. x 0.937 + 0.040 in deep. Tapped withHelicoil Tap No. 6 CPB or 6CS x 0.875 in (min)deep (318 UNC 1.5D insert).NOTE: Right-hand cylinder head illustrated.F Exhaust manifold faceG Intake manifold faceH Front faceRear faceI Front of enginei1 0 REVISED: IUNE 87


;;‘;r; 1987-88-89REMOVE THE FLEXIBLE DRIVE PLATE AND RING:‘ GEAR ASSEMBLYNOTE: To ensure the following componentsare re-assembled in their correct radialpositions, scribe each component with anidentification line to enable each part to bere-assembled in the correct relationship toone another.REMOVE TIMING GEAR COVER AND WATERPUMP1. Place an oil drip-tray beneath the timing coverand remove the oil filter element.2. Remove the crankshaft pulley bolt and specialwasher and withdraw the pulley..:‘.:1.2.3.4.5.Remove the four retaining bolts.Withdraw the clamp ring, flexible drive plate,hub aligner and ring gear assembly.Remove the six socket head bolts securing thecrankshaft adaptor plate and shim to thecrankshaft flange.Withdraw the crankshaft adaptor plate andshim.Inspect the ring gear assembly for distortion,cracks, chipped or badly worn teeth. If ringgear is in poor condition fit a complete newassembly.,’ :‘.3.4.Remove the two bolts securing the sump tothe bottom of the timing cover.Remove the remaining timing cover retainingbolts and withdraw the cover complete withoil pump.RRlBOMRR1796EContinuedREVISED: SEPT. 88 11.,


KANGt1987-88-89 ROVERFit a new timing cover oil seal5.6.7.8.Remove the seven drive screws and withdrawthe mud shield and the oil seal.Position the gear cover with the front faceuppermost and the underside supportedacross the oil seal housing bore on a suitablewooden block.Enter the oil seal, lip side leading, into thehousing bore.Press in the oil seal until the plain face is 1.5mm (0.059 in) approximately below the gearcover face.9. Fit the mud shield and secure with the screws. RR2614EREMOVE AND OVERHAUL THE OIL PUMP1. Remove the bolts from the oil pump cover.2. Withdraw the oil pump cover.3. Lift off the cover and remove the gasket.4. Withdraw the oil pump gears.REMOVE THE DISTRIBUTOR1. Release the single nut securing the distributorclamp.2. Remove the clamp and withdraw thedistributor.3. If necessary overhaul the distributor, (seedistributor overhaul in Section 86 Electrical).REMOVE ENGINE OIL COOLER ADAPTOR PLATE1989 Model Year1. Remove both oil cooler pipes.2. Mark the position of the adaptor plate relativeto the oil pump cover.3. Remove the centre fixing and withdraw theadaptor plate.Dismantlepump5. Unscrew the plug from the pressure reliefvalve.6. Lift the sealing washer from the plug.7. Withdraw the spring from the relief valve.8. Withdraw the pressure relief valve.Refit4. Reverse the removal procedure, lining up thelocation marks to ensure pipe runs are c orrect.Ensure the pipes and centre fixing aretightened to the specified torque, see Torquevalues - section 06.,.-- . .i12 REVISED: SEPT. 88


Examine pump ENGINE OIL PRESSURE TEST9. Check the oil pump gears for wear or scores.IO. Fit the oil pump gears and shaft into the frontcover.11. Place a straight edge across the gears.12. Check the clearance between the straightedge and the front cover. If less than 0.05 mm(0.002 in), check the front cover gear recessfor wear.Special tools:LST502-1: Adaptor pressure take off18G502A: O-300 p.s.i. Pressure guage18G502K: Hose and adaptorsThe following procedure applies to engines thathave completed in excess of 1,000 miles and arefilled with 15W/40 engine oil. The engine must beinstalled in the vehicle.WARNING: Suitable extraction equipment mustbe fitted to the exhaust system of the vehicle, ifthe test is being carried out in the workshop.WARNING: If the vehicle has been running theengine oil will be hot, care must be taken whenfitting the equipment to prevent the possibilityof personal injury due to scalding.TEST:13.14.15.16.Check the oil pressure relief valve for wear orscores.Check the sides of the relief valve spring forwear or signs of collapse.Clean the wire screen filter for the relief valve.Check the fit of the relief valve in its bore. Thevalve must be an easy slide fit with noperceptible side movement.Assemble pump 6.17.18.19.20.21.Insert the relief valve spring.Locate the sealing washer on to the reliefvalve plug.Fit the relief valve plug and tighten to correcttorquefsee section 06-Torque values).Fully pack the oil pump gear housing withPetroleum Jelly. Use only Petroleum lelly; noother grease is suitable.Fit the oil pump gears so that the Petroleumjelly is forced into every cavity between theteeth of the gears.1.2.3.4.5.Place the vehicle on a suitable hoist.Disconnect the battery negative terminal,Remove the bolt from the oil pump housingand install adaptor LST502-1.Fit pressure guage 18G502A to hose 18G502K,fit the hose and guage to adaptor LST502-1.Tighten all joints securely.Connect the battery terminal and ensuring thatthe park brake is applied and that ‘PI or IN’ isselected in the main gearbox start and run theengine. Run the engine until normal engineoperating temperature is achieved (thermostatopen).With the engine speed maintained at 2400rpm there should be a minimum engine oilpressure of 1.76 kg/cm’ (25 p.s.i.)22.23.24.IMPORTANT: Unless the pump is fullypacked with Petroleum Jelly it may notprime itself when the engine is started.Place a new gasket on the oil pump cover.Locate the oil pump cover in position.Fit the special fixing bolts and graduallytighten to the specified torque (see section06-Torque values).RR2354E4REVISED: MARCH 90 13


,987 kAlYutROVERREMOVE TIMING CHAIN SPROCKET ANDCAMSHAFT1. Remove the retaining bolt and washer andwithdraw the distributor drive gear and spacer.2. Withdraw the sprocket complete with timingchain.Examine components4.5.6.Visually examine all parts for wear. Check thecamshaft bearing journals and cams for wear,pits, scores and overheating. Should any ofthese conditions be present fit a newcamshaft.Examine the links and pins of the timing chainfor wear and compare its condition with thatof a new chain. Similarly the teeth of thesprockets should be inspected and ifnecessary fit a new sprocket.Measure the camshaft journals for overall wear,out of roundness and taper. The diameters ofthe five journals are as follows starting fromthe front of the shaft:Number 1 iournal 1.786 to 1.785 in(45.4 to 45.3 mm)Number 2 journal 1.756 to 1.755 in(44.6 to 44.5 mm)Number 3 journal 1.726 to 1.725 in(43.84 to 43.81 mm)Number 4 journal 1.696 to 1.695 in(43.07 to 43.05 mm)Number 5 journal 1.666(42.31 to 42.29 mm)to 1.665 in7. To check the camshaft for straightness rest the .‘. I


o;;; 1987 ENGINE r12- l.‘.REMOVE AND OVERHAUL CONNECTING RODSAND PISTONS1. Withdraw the retaining bolts and remove thesump.2. Remove the sump oil strainer.3. Remove the connecting rod caps and retainthem in sequence for reassembly.4. Screw the guide bolts 605351 onto theconnecting rods.Overhaul7.NOTE: The connecting rods, caps andbearing shells must be retained in sets, andin the correct sequence. Remove the pistonrings over the crown of the piston. If thesame piston is to be refitted, mark itrelative to its connecting rod to ensure thatthe original assembly is maintained.Withdraw the piston pin, using toot 18C 1150as follows:5.6.Push the connecting rod and piston assemblyup the cylinder bore and withdraw it from thetop. Retain the connecting rod and pistonassemblies in sequence with their respectivecaps.Remove the guide bolts 605351 from theconnecting rod.e.f.g.h.i.i.Clamp the hexagon body of 1% 1150 ina vice.Position the large nut flush with the endof the centre screw.Push the screw forward until the nutcontacts the thrust race.Locate the piston adaptor 18C 1150Ewith its long spigot inside the bore ofthe hexagon body.Fit the remover/replacer bush of 18GII SO on the centre screw with theflanged end away from the piston pin.Screw the stop-nut about half-way ontothe smaller threaded end of the centrescrew, leaving a gap ‘A’ of 3 mm (l/8 in)between this nut and the remover/replacer bush.Lock the stop-nut securely with the lockscrew.Check that the remover/ replacer bush iscorrectly positioned in the bore of thepiston.Push the connecting-rod to the right toexpose the end of the piston pin, whichmust be located in the end of theadaptor ‘d’.Screw the large nut up to the thrust race.Continued


‘..Ik. Hold the lock screw and turn the largenut until the piston pin has be&withdrawn from the piston. Dismantle thetool.A .:I18G1150“79 f 8 d a CSWM,‘....,..’i16.:’:.,. .‘. ., .:: ;


:.KMIYUCROVER lg8’ ENGINE 1121Originalpistons8. Remove the carbon deposits, particularly fromthe ring grooves. Examine the pistons for signsof damage or excessive wear; refer to ‘newpistons’ for the method of checking therunning clearance. Fit new pistons if necessary.10.Check the piston dimension at right angles tothe piston pin, at the bottom of the skirt.New pistons‘.‘.:‘,.-.NOTE: Pistons are available in servicestandard size and in oversizes of 0.25 mm(0.010 in) and 0.50 mm (0.020 in). Servicestandard size pistons are supplied 0.0254mm (0.001 in) oversize. When fitting newservice standard size pistons to a cylinderblock, check for correct piston to boreclearance, honing the bore if necessary.Bottom of piston skirt/bore clearanceshould be 0.016 to 0.033 mm (0.0007 to0.0013 in).NOTE: The temperature of the piston andcylinder block must be the same to ensureaccurate measurement. When reboring thecylinder block, the crankshaft main bearingcaps must be fitted and tightened to thecorrect torque (see section 06.TorqueValues).11.12.The piston dimension must be 0.018 to 0.033mm (0.0007 to 0.0013 in). smaller than thecylinder.lf new piston rings are to be fitted withoutreboring, deglaze the cylinder walls with ahone, without increasing the bore diameter, toprovide a cross-hatch finish. After honing,thouroughly clean the piston bores to removeall traces of foreign matter.‘_’9. Check the cylinder bore dimension at rightangles to the piston pin 40 to 50 mm (1.5 to 2REVISED: MARCH 90 17


13. Check the compression ring in the applicablecylinder, held square to the bore with thepiston. Gap limits: 0.44 to 0.56 mm (0.017 to0.022 in). Use a fine-cut flat file to increasethe gap if required. Select a new piston ring ifthe gap exceeds the limit.NOTE: Gapping does not apply to oilcontrol has. ,/ - \\ -L. t.Fit piston rings14.15.16.STslQM /Temporarily fit the compression rings to thepiston.The ring marked ‘TOP’ must be fitted with themarking uppermost and into the secondgroove. The chrome ring is for the top grooveand can be fitted either way round.Check the compression ring clearance in thepiston groove. Clearance limits: 0.05 to 0.10mm (0.002 to 0.004).17.18.19.Fit the expander ring into the bottom groovemaking sure that the ends butt and do notoverlap.Fit two ring rails to the bottom groove, oneabove and one below the expander ring.Fit the second compression ring with themarking iTOP’ uppermost and the groove,either way round.19‘,,“‘5; .’.‘:t18 REVISED: MARCH 90:i i..


KMNUCROVER ls8’ENGINE1121,.-_Examine connecting rods20. Check the alignment of the connecting rod.21. Check the connecting rod small end, thepiston pin must be a press fit.Check crankshaft bearings22. Locate the bearing upper shell into theconnecting rod.23. Locate the connecting rod and bearing ontothe applicable crankshaft journal, noting thatthe domed shape boss on the connecting rodmust face towards the front of the engine onthe right hand bank of cylinders and towardsthe rear on the left hand bank.24. When both connecting rods are fitted, thebosses will face inwards towards each other.25.26.27.20.29.Place a piece of Plastigauge (PGI) across thecentre of the lower half of the crankshaftjournal.Locate the bearing lower shell into theconnecting rod cap.Locate the cap and shell onto the connectingrod. Note that the rib on the edge of the capmust be on the same side as the domedshape boss on the connecting rod.Secure the connecting rod cap. Tighten to thecorrect torque (see section 06-Torque values).Do not rotate the crankshaft or connectingrod while the Plasiigauge is in use.Continued


RANGE“*’ ROVER30. Remove the connecting rod cap and shell.31. Using the scale printed on the Plastigaugepacket, measure the flattened Plastigauge at itswidest point.32. The graduation that most closely correspondsto the width of the Plastigauge indicates thebearing clearance.33. The correct bearing clearance with new oroverhauled components is 0.015 to 0.055 mm(0.0006 to 0.0022 in).34. If a bearing has been in service, it is advisableto fit a new bearing if the clearance exceeds0.08 mm (0.003 in).35. If a new bearing is being fitted, use selectiveassembly to obtain the correct clearance.36. Wipe off the Plastigauge with an oily rag. DONOT scrape it off.NOTE: It is important that the connectingrods, caps and bearing shells be retained insets, and in the correct sequence.Assembling pistons to connecting rods i.37. Using tool 18G 1150 refit each piston to itsconnecting rod as follows:a. Clamp the hexagon body of 1 FIG 1150 ina vice, with the adaptor 18G 1150 Epositioned as in 7d.b. Remove the large nut of 18C 1150 andpush the centre screw approximately 50mm (2 in) into the body until theshoulder is exposed.C. Slide the parallel guide sleeve, groovedend last, onto the centre screw and upto the shoulder.d.e.f.f5h.i.k.Lubricate the piston pin and bores of theconnecting rod and piston with graphitedoil (Molykore 2). Also lubricate the ballrace and centre screw of 18C 1150.Fit the connecting rod and the pistontogether onto the tool with the markingsaligned if the original pair are being usedand with the connecting rod around thesleeve up to the groove.Fit the piston pin into the piston bore,up to the connecting rod.Fit the remover/replacer bush 18C 11 SO/3with its flanged end towards the pistonpin.Screw the stop nut onto the centrescrew and adjust this nut to obtain an 0.8mm (0.031 in) end float ‘A’ on the wholeassembly, and lock the nut securely withthe screw.Slide the assembly back into the hexagonbody and screw on the large nut up tothe thrust race.Set the torque wrench 18G 537 to 16Nm (12 ft lb). This represents theminimum load for an acceptableinterference fit of the piston pin in theconnecting rod.Using the torque wrench and socket l&X587 on the large nut, and holding thelock screw, pull the piston pin in untilthe flange of the remover/replacer bushis 4mm (0.157 in) ‘B’ from the face of thepiston. Under no circumstances must thisflange be allowed to contact the piston.,i2 0


.;;“d;‘;r; 1987 ENGINE 1121CAUTION: If the torque wrench has notreached at least 12 ft.lbs throughout thepub the fit of the piston pin to theconnecting rod is not acceptable andnecessitates the fitting of new components.The large nut and centre screw of the toolmust be kept well oiled.18G.1150; :..,, ‘...: ‘..:::,.’ .’ ‘,:.I.?, ,‘.38. Remove the tool and check that the pistonmoves freely on the piston pin and that nodamage has occurred during pressing.


REMOVE AND OVERHAUL CRANKSHAFT1. Remove the main bearing caps and lowerbearing shells and retain in sequence. It isimportant to keep them in pairs and markthem with the number of the respectivejournal until it is decided if the bearing shellsare to be refitted.2. Lift out the crankshaft and rear oil seal.,.‘*. I‘. :‘. ., 22,‘,,, .’,:, .“, .:, .‘.‘I.‘.._..


Inspect and overhaul crankshaft3. Rest the crankshaft on vee-blocks at numbersone and five main bearing journals.4. Using a dial indicator, check the run-out atnumbers two, three and four main bearingjournals. The total indicator readings at eachjournal should not exceed 0.08 mm (0.003 in).9. The centre main bearing shell, which controlscrankshaft thrust, has the thrust facesincreased in thickness when more than 0.25mm (0.010 in) undersize, rs shown on thefollowing chart.‘.56.7.8.While checking the run-out at each journal,note the relation of maximum offset on eachjournal to the others. The maximum on alljournals should all come at very near the sameangular location.If the crankshaft fails to meet the foregoingchecks it is bent and is unsatisfactory forservice.Check each crankshaft journal for out ofround. If the out of round exceeds 0.040 mm(0.0016 in) around the crankshaft journal, areground or new crankshaft should be fitted.Bearings for the crankshaft main journals andthe connecting rod journals are available in thefollowing undersizes:0.25mm (0.010 in)0.50mm (0.020 in)10. When a crankshaft is to be reground, thethrust faces on either side of the centre mainjournal must be machined in accordance withthe dimensions in the charts that follow:11. For example: If a 0.50 mm (0.020 in) undersizebearing is to be fitted, then 0.12 mm (0.005in) must be machined off each thrust face ofthe centre journal, maintaining the correctradius.Crankshaftdimensions12. The radius for all journals except the rear mainbearing is 1.90 to 2.28 mm (0.075 to 0.090 in).13. The radius for the rear main bearing journal is3.04 mm (0.120 in).Continued


14. Main bearing journal diameter, see thefollowing charts.15. Thrust face width, and connectingdiameter, see the following charts.rod journalCrankshaftdimensions-millimetreCrankshaftGradeDiameter'12'Width'13'Diameter'14'Standard 58.400-58.4120.254 U/S 58.146-58.1580.508 U/S 57.892-57.90426.975-27.026 50.800-50.81226.975-27.026 50.546-50.55827.229-27.280 50.292-50.304Crankshaft dimensions - inchesCrankshaftGradeDiameter'12'Width'13'Diameter'14'Standard 2.2992-2.29970.010 u/s 2.2892-2.28970.020 u/s 2.2792-2.27971.062-1.064 2.0000-2.00051.062-1.064 1.9900-1.99051.072-1.074 1.9800-1.9805Check main bearing clearance16.17.18.19.20.21.Remove the oil seals from the cylinder blockand the rear main bearing cap.Locate the upper main bearing shells into thecylinder block. These must be the shells withthe oil hole and oil grooves.Locate the flanged upper main bearing shell inthe centre position.Place the crankshaft in position on thebearings.Place a piece of Plastigauge across the centreof the crankshaft main bearing journals.Locate the bearing lower shell into the mainbearing cap.22. Fit numbers one to four main bearing capsand shells, tighten to the correct torque (seesection 06-Torque values).‘- .. ‘.,,Y..24


‘.’:,. ,.’ t23.24.25.26.27.28.29.30.Fit the rear main bearing cap and shell andtighten to the correct torque (see sectionOC-Torque values). Do not allow the crankshaftto be rotated while the Plastigauge is in use.Remove the main bearing caps and shells.Using the scale printed on the Plastigaugepacket, measure the flattened Plastigauge at itswidest point.The graduation that most closely correspondsto the width of the Plastigauge indicates thebearing clearance.The correct bearing clearance with new oroverhauled components is 0.023 to 0.065 mm(0.0009 to 0.0026 in).If the correct clearance is not obtained initially,select a suitable bearing to give the requiredclearance.Wipe off the Plastigauge with an oily rag. DoNOT scrape it off.Maintain the bearing shells and caps in setsand in the correct sequence.ASSEMBLINGENGINEFIT CRANKSHAm AND MAIN BEARINGS *:+I. Locate the upper main bearing shells into thecylinder block; these must be the shells withthe oil holes and oil grooves.2. Locate the flanged upper main bearing shell inthe centre position.3. Lubricate the crankshaft main bearing journalsand bearing shells with clean engine oil andlower the crankshaft into position.‘.::..’::’,’ .’: :,’ ‘1,‘.--‘,’4.5.6.Lubricate the lower main bearing shells and fitnumbers one to four main bearing caps andshells only, leaving the fixing bolts finger-tightat this stage.Fit the cross shaped side seals to the grooveseach side of the rear main bearing cap. Do notcut the side seals to length, they mustprotrude 1.5 mm (0.062 in) approximatelyabove the bearing cap parting face.Apply Hylomar SQ32M jointing compound tothe rearmost half of the rear main bearing capparting face or, if preferred, to the equivalentarea on the cylinder block as illustrated.Lubricate the bearing half and bearing cap sideseals with clean engine oil.Fit the bearing cap assembly to the engine. Donot tighten the fixings at this stage but ensurethat the cap is fully home and squarely seatedon the cylinder block.Tension the cap bolts equally by one-quarterturn approximately, th& back off onecomplete turn on each fixing bolt.Continued25


I. -. I.1987 wNCltROVERST831M ’ -II \10.11.CAUTION: Do not handle the oil seal lip,visually check that it is not damaged andensure that the outside diameter remainsclean and dry.Position the seal guide RO 1014 on thecrankshaft flange.Ensure that the oil seal guide and thecrankshaft journal are scrupulously clean, thencoat the seal guide and oil seal journal withclean engine oil.13. Tighten the main bearing cap bolts to thecorrect torque (see section 06.Torque values)noting that the bolts for numbers one to fourbearings have a different torque to numberfive bearing cap bolts.14. Using a feeler gauge or a dial indicator checkthe crankshaft end-float, 0.10 to 0.20 mm(0.004 to 0.008 in).NOTE: The lubricant coating must cover theseal guide outer surface completely toensure that the oil seal lip is not turnedback during assembly.Position the oil seal, lipped side towardsthe engine, on to the seal guide. The sealoutside diameter must be clean and dry.:..’12.Push home the oil seal fully and squarely byhand into the recess formed in the cap andblock until it contacts the machined step inthe recess.Withdraw the seal guide.CAUTION: Do not exceed 1,000 enginerev/min for 15 seconds when first startingthe engine, otherwise the crankshaft rearoil seal will be damaged.:26.d;-,.: _‘.


6. Engage the sprocket assembly on the camshaftand crankshaft key locations and check thatthe camshaft key is parallel to the shaft axis toensure adequate lubrication of the distributordrive gear.8. Fit the distributor drive gear ensuring that theannular grooved side is fitted to the rear, thatis towards the spacer.9. Secure the drive gear and camshaft sprocketassembly with the bolt and washer and tightento the correct torque (see section 06-Torquevalues).RR 18OlECAUTION: The space between the key andkeyway acts as an oilway for lubrication ofthe drive gear. Ensure that the key is seatedto the full depth of the keyway. The overalldimension of shaft and key must notexceed 30.15 mm (1.187 in). Dimension Abelow.ST841MI7. Check that the timing marks line up and fit thespacer with the flange to the front.cREVISED: DEC. 87 29 ;.


1987 IWNbtROVERFIT THE RING GEAR AND FLEXIBLE DRIVE PLATEASSEMBLY1. Fit the shim and crankshaft adaptor plate tothe crankshaft flange noting the previouslymarked identification lines and secure inposition with the six socket head bolts. Donot fully tighten the bolts at this stage.2. Fit the ring gear assembly, hub aligner, flexibledrive plate noting the previously markedidentification lines and secure in position withthe four bolts and clamping ring. Do not fullytighten the bolts at this stage.‘.j..‘.; :’,: I: ‘:‘.‘.‘. .:: .,.’.‘,‘. ‘,.‘.3.4.To ensure that there is no distortion to theflexible drive plate when bolted to the torqueconverter, check the setting height of thedrive plate as follows.To prevent excessive clearance, a shim is fittedbetween the crankshaft drive flange andcrankshaft adaptor plate. The setting height,dimension A, is measured between the frontface of the ring gear drive plate and enginecylinder block to gearbox mating face, adimension of 8.08 to 8.20 mm (0.318 to 0.323in) is to be maintained. Should this dimensionnot be achieved a selection of shims inprogressive thicknesses is available. Select theappropriate shim to maintain the dimension, asshownbelow.PART NO. DIMENSION (MM)KEY:1.2.3.4.5.6.7.Crankshaft flange.Shim.Crankshaft adaptor flange.Drive plate and ring gear assembly.Hub aligner.Flexible drive plate.Clamp ring..’::,‘.FRC 7084 1.20 - 1.25FRC 7085 1.30 - 1.35FRC 7086 1.40 - 1.45FRC 7087 1.50 - 1.55FRC 7088 1.60 - 1.65FRC 7089 1.70 - 1.75FRC 7090 1.80 - 1.85FRC 7091 1.90 - 1.95FRC 7092 2.00 - 2.05FRC 7093 2.10 - 2.15., ,:I.;: :,::.:::30 REVISED: DEC. 87.‘. .‘,‘.


5.6.7.8.9.Remove the four bolts clamp ring flexible driveplate hub aligner and ring gear assembly.Remove the six socket head bolts andcrankshaft adaptor.Fit the appropriate shim, refit the adaptor andsix socket head bolts, tighten to the specifiedtorque (see section 06-Torque values).Fit the ring gear assembly, hub aligner, flexibledrive plate and clamp ring.Coat the threads of the four securing boltswith Loctite 270 prior to assembly, fit the boltsand tighten to the specified torque (seesection 06.Toque values).‘,‘;...,y: :‘“:.‘;.y., .;.FIT CYLINDER HEADS1. Fit new cylinder head gaskets with the word‘TOP’ uppermost. Do NOT use sealant.4. Locate the cylinder head bolts in position asillustrated and fit dipstick tube.Long bolts - I, 3 and 5.Medium bolts - 2,4,6,7,8,9 and 10.Short bolts - 11,12,13 and 14.5. Tighten the cylinder head bolts a little at atime in the sequence shown. (See sectionOC-Torque values for correct tighteningtorque).6. When all bolts have been tightened, recheckthe torque values.2. Locate the cylinder heads on the block dowelpins.3. Clean the threads of the cylinder head boltsthen coat them with Thread Lubricant-SealantLoctite 572.STS45MNOTE: left-hand cylinder head illustrated.Arrow points to front of vehicle.ContinuedREVISED: IUNE 87 3 1,‘. ,’


FIT TAPPETS, PUSH RODS AND ROCKERASSEMBLIESFit tappets and push rods4. Fit the rocker shaft assemblies. Ensure that thepushrods engage the rocker cups. Tighten thebolts to the correct torque (see Section 06 -TorqueValues).1. Fit the tappets and push rods to their originallocations, Ensure that the tappets move freelyin their respective bores. Before fitting thetappets immerse them in clean engine oil toreduce tappet noise when the engine is firststarted after the overhaul.Fit the rocker assemblies2. The rocker shafts are handed and must befitted correctly to align the oilways.3. Each rocker shaft is notched at one end andon one side only. The notch must beuppermost and towards the front of theengine on the right hand side, and towardsthe rear on the left hand side.It should be noted that tappet noise can beexpected on initial starting up after anoverhaul due to oil drainage from the tappetassemblies or indeed if the vehicle has beenstanding over a very long period. If excessivenoise should be apparent after an overhaul,the engine should be run at approximately2,500 rev/min for a few minutes (subject tothe following caution), when the noise shouldbe eliminated.CAUTION: Do not exceed 1,000 enginerev/min for 15 seconds when first startingthe engine, othemise the crankshaft rearoil seal will be damaged.,.’.32 REVISED: JUNE 87


FIT THE INTAKE MANIFOLD1. Apply a globule of Hylomar SQ32M sealingcompound to the notches formed betweenthe cylinder head and block.2. Locate the NEW seals in position with theirends engaged in the notches formed betweenthe cylinder heads and block.6. Locate the manifold on to the cylinder head.7. Clean the threads of the manifold securingbolts.8. Fit all the manifold bolts and tighten them alittle at a time, evenly, alternate sides workingfrom the centre to each end and finally tightento the correct torque (see section 06-Torquevalues).9. Tighten the gasket clamp bolts to the correcttorque (see section 06-Torque values).Apply ‘Hyfomar’ SQ32M sealing compound onthe corners of the cylinder head, manifoldgasket and manifold, around the water passagejoints.Fit the manifold gasket with the word ‘FRONT’to the front and the open bolt hole at thefront R.H. side.Fit the gasket clamps but do not fully tightenthe bolts at this stage.)’ i,:‘:-:‘.F.. :.‘.yu, ...‘..REVISED: IUNE 87


c.FIT THE TIMING COVER AND CRANKSHAmPULLEY1.2.3.4.5.Place a new timing cover joint washer inposition and fit the timing cover locating it onthe two dowels.Clean the threads of the timing cover securingbolts, then coat them with ThreadLubricant-Sealant Loctite 572.Fit and evenly tighten the timing cover boltsto the correct torque (see section OL-Torquevalues).Fit the crankshaft pulley and tighten theretaining bolt to the correct torque (seesection 06-Torque values).Fit timing pointer,4. Leave the alternator adjusting link loose andtighten the remaining water pump housingbolts evenly and to the correct torque (seesection 06-Torque values).‘..-.,RR1795L.’FIT THE SUMP‘:,,;:1. Remove any traces of previous sealant fromthe sump and cylinder block joint faces.2. Apply a 2 mm (0.08 in) wide bead of Hylosil102 to the joint face of the sump as shown inthe illustration below.x,., ‘,1.L.*y.A. . . ...“” :”%f%E WATER PUMPLightly grease a new joint washer and place itin position on the timing cover.Clean the threads of the four long bolts andcoat them with Loctite 572 thread lubricantsealant.Locate the water pump in position.Locate the alternator adjusting link on thewater pump.RRl887E3.4.Place the sump in position, fit the sump boltsand evenly tighten the bolts to the specifiedtorque (see section 06-Torque values).Allow the vehicle to stand for a period of 30minutes to ensure that the H$losil is cured.Failure to do so could possibly result inrepeating the sump fitting operation...I!. . .II..’., .;. :’ ,.. .,34 REVISED: IUNE 87,. .’ :.,:.,.,,:: .,. .‘.


!.;;^d;;i; 1987ENClNE(121:.’ ‘,.‘.TEST AND FIT THE THERMOSTAT.::.;1.2.3.Remove the two bolts securing the thermostathousing to the intake manifold.Remove the housing gasket.Withdraw the thermostat.‘.Sr855M ! I I I9. Fit the thermostat with the jiggle pinuppermost at 12 o’clock.10. Fit the housing using a new gasket, andtighten the two bolts to the correct torque(see section 06-Torque values).RR179lEFIT THE DISTRIBUTOR4.Note the temperature stamped on thethermostat at which it should be fully open,88°C (190°F).Turn the crankshaft to bring number onepiston to 6” BTDC on the compression stroke(both valves closed number one cylinder).Turn distributor drive until rotor arm isapproximately 30” counter-clockwise fromnumber one spark plug lead position on cap.Turn the oil pump and distributor commondrive shaft so that the tongue is in theapproximate position as illustrated.45.6.7.8.Place the thermostat and a Centigradethermometer in a laboratory beaker, or asuitable alternative, half full of water.Heat the water and observe the temperatureat which the thermostat opens.If faulty discard the thermostat.Clean the intake manifold and thermostathousing mating faces.Continued4. :. .;,; ..:‘.;.,.‘:_;:.;,REVISED: APR.87 35


n12 FNGINE4.5.6.Fit the distributor to the engine and check thatthe centre line of the rotor arm is now in linewith number one spark plug lead position inthe distributor cap. Reposition distributor ifnecessary. The vacuum capsule should be atapproximately 90” to the camshaft.If distributor does not seat correctly in frontcover, oil pump drive is not engaged. In thisevent, remove distributor, reset oil pump drivetongue as necessary, and repeat operation.Fit the clamp and nut leaving both loose atthis stage.I&-8RR1676EFIT ROCKER COVERS1.2.3.Remove all traces of old gasket and sealantfrom the covers and cylinder heads.Clean and dry the gasket mounting surface,using Bostik cleaner 6001.Apply Bostik 1775 impact adhesive to the sealface and the gasket, using a brush to ensurean even film. Allow the adhesive to becometouch-dry, after approximately fifteen minutes.7.Rotate the distributor until the peak on thepick-up lines up with a peak on the reluctorring. The rotor arm may be removed to afforda better view.NOTE: The gasket fits one way round onlyand must be fitted accurately first time; anysubsequent movement would destroy thebond.CAUTION: On no account must the enginebe started before this operation is carriedout.8.9.Secure the distributor in this position bytightening the clamp nut.Fit the distributor cap and spark plugs andconnect the H.T. leads in accordance withillustration RR. 1876E.NOTE: The above distributor setting is toenable the engine to be run so that thecorrect setting given in ‘Engine Tuning Data’can be achieved once the engine is refittedto the vehicle.Continued36 REVISED: APR.87.


R";;; 1987-88-89.,..I..,,: ::, :.: I,.. :::....._..4. Place one end of the gasket into the coverrecess with the edge firmly against the recesswall: at the same time hold the remainder ofthe gasket clear; then work around the cover,pressing the gasket into place ensuring thatthe outer edge firmly contacts the recess wall.5. Allow the cover to stand for thirty minutesbefore fitting it to the cylinder heads.6. Secure the rocker covers to the cylinder headswith the four screws. Short screws inboard,long screws outboard.FIT ENGINE OIL FILTERRR2618S shows 1989 Model Year condition1. Clean the oil pump/oil cooler adaptor matingface.2. Coat the sealing ring of the new filter withclean engine oil.3. Fill the filter with new oil as far as possible,noting the angle at which the filter is to befitted.4. Screw on the filter until the sealing ringtouches the oil pump/oil cooler mating face,then tighten it a further half turn by hand only.Do not over-tighten.5. Refill the engine with the specified grade andquantity of oil.FIT EXHAUST MANIFOLD1. Ensure that the mating surfaces of the cylinderhead and exhaust manifold are clean, fit newgaskets to the exhaust manifold and coat thethreads of each bolt with anti-seizecompound.2. Place the manifold in position on the cylinderhead and fit new lockplates, securing bolts,and plain washers. The plain washers are fittedbetween the manifold and lockplates. Evenlytighten the manifold bolts to the correcttorque (see section 06-Torque values) andbend over the lock tabs.. ,.:..:MISCELLANEOUS AND NON-STANDARD ITEMSFit any other items of equipment and miscellaneoushoses, pipes, filters, clips and brackets to thepositions noted during dismantli;g.REVISED: SEPT. 88 37 :.,,::,..;.::.I-


9.10.11.12.13.Place the bearing lower shell in the connectingrod cap.Locate the cap and shell onto the connectingrod, noting that the rib on the edge of thecap must be towards the front of the engineon the right hand bank of cylinders andtowards the rear on the left hand bank.Check that the connecting rods move freelysideways on the crankshaft. Tightness indicatesinsufficient bearing clearance or a misalignedconnecting rod.Check the end-float between theconnecting-rods on each crankshaft journal.Clearance limits: 0.15 to 0.37 mm (0.006 to0.015 in).Tighten the connecting rod nuts to the correcttorque (see section 06-Torque values). Fit theoil strainer and joint washer.FIT CAMSHAFT TIMING CHAIN AND SPROCKETI. Lubricate the camshaft journals and carefullyinsert the camshaft into the cylinder block.Turn the crankshaft to bring number onepiston to TDC.Temporarily fit the camshaft sprocket with themarking IF’ or ‘FRONT’ outward.Turn the camshaft until the mark on thecamshaft sprocket is at the six o’clockposition, then remove the sprocket withoutdisturbing the camshaft.Encircle the sprockets with the chain keepingthe timing marks aligned.:,.: ‘,28 REVISED: DEC. 87


,. ;:..FIT CONNECTING RODS AND PISTONS1. Locate the applicable crankshaft journal atB.D.C.2. Place the bearing upper shell in theconnecting rod.3. Retain the upper shell by screwing the guidebolts 605351 onto the connecting rods.4. Insert the connecting rod and piston assemblyinto its respective bore, noting that thedomed shape boss on the connecting rodmust face towards the front of the engine onthe right hand bank of cylinders and towardsthe rear on the left hand bank. When bothconnecting rods are fitted, the bosses will faceinwards towards each other.7. Using a piston ring compressor, locate thepiston into the cylinder bore, until the pistoncrown is just below the cylinder block topface.8. Pull the connecting rods on to the crankpinsusing the guide rods. Use extreme care whenpulling the pistons down their respectivebores to prevent scratching the crank pins.:,. . .5. Position the oil control piston rings so that thering gaps are all at one side, between thepiston pin and piston thrust face. Space thegaps in the ring rails approximately 25 mm (1in) each side of the expander ring joint.6. Position the compression rings so that theirgaps are on opposite sides of the pistonbetween the piston pin and piston thrust face.iContinued;J6'5REVISED: DEC. 87


-l 12 ENGINE1987-88-89 ;I^d';;;FAULTDIAGNOSISNOTE: The following fault diagnosis charts are intended as a guide only, having determined thepossible fault refer to the appropriate section within the manual.The charts have been updated to include 1989 Model Year charcoal canister and purge valve. Refer toEmmission Control - Section 17 and Fuel Injection System - Section 19 for full details of charcoalcanister/purge valve.ELEC;RICALENGINE FAILS TO STARTI 1FtiELIBattery in lowstate of chargeCheck and rechargeor replace1Is there sufficientfuel in tankCheck and refillas necessaryIIncorrectStartingProcedureRefer to Driver’sHandbookBlocked I air filter Check and replaceas necessaryElec I ricalFaultCheck all harnessesand connectionsFaulty fuel pumpRefer lo fuelinjection systemfault diagnosis.:..:.: .Starter motorspeed too slowCheck batteryand connectionsBlockage in fuelsystemCheck fuelsystem (refer tofuel injectionsystem faultdiagnosis)Defectivestarter motorRemove startermotor andoverhaul (referto electricalsection)Fuel injection Refer to fuelsystem -- injection systemmalfunctionfault diagnosisStarter pinionnot engagedIRemove startermotor andoverhaul (referto electricalsection)ignitionsystemCheck and fitnew componentsas necessan/(refer toelectricalsection),.I,... *:..:. !.‘. ‘;.,,.I, y,.,., :.3 8 REVISED: SEPT. 88


IIII-..’ .,IELECTRICALENGINE FAILS TO IDLEIFUELIIncorrect enginesettingsRefer to fuelinjection systemFaulty By-pass Refer to fuelair valveinjection system(stepper motor)fault diagnosisUn-metered airentering engineCheck for airleaksIPurge valve Check operation offully open purge valve.See tests 9 and 10- Section 19ENGINESTALLSIELECTRICAL1FUELIDefectiveignitionsystemRefer toelectricalsectionILow idling speedCheck for airleaks insystem.‘.,‘:Contan!inatedfuel systemInvestigatesource ofcontamination.Clean fuelsystem asnecessaryPurge valvefully openCheck operation ofpurge valve.See tests 9 and 10- Section 19NOTE: SMELL OF PETROL IN ENGINE COMPARTMENT, POSSIBLE CAUSE: PURGE VAt$‘E STUCK CLOSED(NO PURGE ON CHARCOAL CANISTER) See tests 9 and 10 - Section 19.Continued,.:;:.;.,;j//.-- ‘.i,, ,IREVISED: SEPT. 88 39‘. ::., ,’ ,,,“1.‘. .‘.‘i


IIII1987-88-89 r;";r;.- ',.ELECTRICALENGINE STARTS, BUT STOPS IMMEDIATELYIFUELIFaultyelectricalconnectionsCheck andsecure asnecessaryIs there sufficientfuel in tankCheck andreplenishas necessary:.. . .IFaultyignitionswitchCheck or replaceswitch (referto electricalsection)Faulty fuelpump/fuelinjectionsystemRefer to fuelinjection systemfault diagnosisIPurge valvefully openCheck operation ofpurge valve.See tests 9 and 10- Section 19: .:” :‘,. ENGINE MISFIRES ON ACCELERATIONIELECTRICALFUELIFaultydistributorcap, rotorarmCheck and replaceas necessaryIFaultyfuel injectionsystemRefer to fuelinjection systemfault diagnosisIFaulty HTand LTleadsCheck and replaceas necessaryPurge valvefully openCheck operation ofpurge valve.See tests 9 and 10- Section 19FaultyignitionsystemRefer toelectricalsystem40 REVISED: SEPT. 88


Iro”v‘;r; 1987-88-89ENClNE112I. .I ‘.rELECTRICALIFaultyelectricalconnectionsCheck, repairor secure asnecessaryENGINE RUNS ERRATICALLYFCjELIBlocked airfilterCheck and replaceas necessaryIDefectivedistributorRefer toElectricalSectionFaulty pressureregulator(high and lowpressure)Refer to fuelinjection systemIncorrectignitiontimingCheck and adjustas necessaryIContaminatedfuelFlush systemand replace fuelFuel systemmalfunctionRefer to fuelinjection systemfault diagnosisPurge valvefully openCheck operation ofpurge valve.See tests 9 and 10- Section 19MECHANICALVacuum hosesdisconnected ordamagedReconnect orreplace as necessaryBeiowrecommendedcylinderpressureIFaulty cylinderhead gasketsCheck withcompressiontwwReplace cylinderhead gasketsIWorn valveor valve guidesContinued4heads.i.,“.-: ::.REVISED: SEPT. 88 41 .‘s\...


II,KANGE1987-88-89 ROVeRLACK OF POWER. .ELECTRICALFaultyplugssparkCheck, adjustor replace1FUELIFaultyPotentiometerRefer to fuelinjectionsystem faultdiagnosisincorrectignitiontimingCheck and adjustas necessaryLeaks orrestrictionsin fuel systemRefer to fuelsystem faultdiagnosis:.FaultyIgnitionsystemRefer toelectrical sectionFaulty pressureregulator(low pressure)Refer to fuelinjection systemfault diagnosis:.IContaminatedfuel systemInvestigatesource ofcontaminationand clean asnecessaryMECtNICALIBelowrecommendedcylindercompressionCheck withcompressiongaugeFaulty I ylinder Replace cylinderhead gaskets head gasketsIWorn pistonsor valvesOverhaul cylinderheads, cylinderblock and pistonsFaulty exhaust Check for leakingsystemsystem, fit newcomponents asnecessary,.l...1.4 2 REVISED: SEPT. 88


,’ ‘. ;;^d;;; 1987ENGINE (121:,,..; ‘.,ENGINEIKNOCKSELECTRICALMECHANICALIIIgnitionCheck andIncorrect fuelDrain andtiminRadiust asin systemrefill withadvanced necessary correct gradeof fuel.(Refer toSection 09 fuelrequirements).IDistributoradvancemechanismfaulty(fully advanced)Check andreplace asnecessaryWorn pistons,crankshaftand bearingsRefer toengine overhaulprocedures1:ENGINE BACKFIRESIELECTRICAL1FUELIIncorrectstartingprocedureRefer to Driver’sHandbookIIncorrectair/fuelratioRefer to fuelinjectionsystem faultdiagnosisIgnitiontimingretardedCheck and adjustas necessaryMECkNICALAir:aksICheck for air leaks aroundplenum chamber to ramhousing, ram housing tointake manifold, intakemanifold to cylinder heads,rectify as necessary.Check condition of injector‘0’ rings, replace if necessary.Check conditi;n and securityof all hoses to and fromplenum chamber. Replace orsecure as necessary.1Check condition and joints ofexhaust system, rectify orreplace.4Continued


III1987 MNGtROVER1NOISY VALVE MECHANISMMECHANICALIWorn or scoredparts in valveoperatingmechanismOverhaul cylinderheadI‘..Weak valvespringsOverhaul cylinderheadTapping noisewhen engineis started andcontinues atidleCheck oil pressureWorn tappet bodyfaulty hydraulictappet(s)Investigatereplace as necessaryIWorn camshaftInvestigatereplace as necessaryMAIN BEARING RATTLEMECHANICALLow oil levelin sumpCheck and replenishas necessaryILow oil pressureCheck oil pressureIWorn bearings/excessiveclearanceCheck/overhaulcylinder block andcrankshaft44


IIR”d;‘;; 1987ENGINE (121ENGINEOVERHEATINGELECTRICALIMECHANICALDefective gaugeor temperaturesender unitCheck andreplace asnecessaryILow coolantlevelCheck forleaking system.Check coolantlevel inexpansion tank,replenish asnecessaryIncorrectignitiontimingCheck andadjust asnecessaryFan beltslippingCheck andadjustIBlockedradiatorcoreFaultythermostatClean asnecessaryTest and replaceas necessaryIWater pumpseizedCheck thatwater pumppulley rotates-replace asnecessaryBlockageradiatorinDrain, flushand refillas necessaryContinued45


III1987 r(ANbtROVER-, .,‘.IIOIL PRESSURE WARNING LIGHT REMAINS ON, ENGINE RUNNING.- .-\I :ELECTRICALMECHANICALFaulty oil Check and replace Low oil level Check replenishpressureas necessaryas necessarysensorFaulty lowoil levelwarning sensorIFaultyelectricalcircuitCheck oil level-replace switchif necessaryCheck wiringcircuitILow oil pressure Check reliefvalve andspringChec Landoverhaul oilpump ifnecessary,1.J.,,‘.a ‘.’x.( :.:... .:.,.46 .’I., :/,.


‘.‘.;;^d;‘;r; 1987EMISSION CONTROL I17 1“l.,\. -.,. ::EMISSIONSEMISSION AND EVAPORATIVE CONTROLRange Rovers are fitted during manufacture withvarious items of emission and evaporative controlequipment to ensure that they meet stringentexhaust emission regulations.Unauthorised replacement or modification of theemission or evaporative control equipment willinvalidate the Emission Warranties and render theuser and/or repairer liable to legal penalties.CRANKCASE CONTROL SYSTEMClean air is drawn into the crankcase via an intakefilter located at the rear of the left hand rockercover.Crankcase emissions and clean air are drawnthrough a breather filter located at the front of theright hand rocker cover into the plenum chamberand then burnt in the engine.EVAPORATIVE EMISSION CONTROL SYSTEMThis system prevents fuel vapour from reaching theatmosphere. The system consists of a fuelexpansion tank located between the inner righthand body side and rear right hand fender, and anadsorption canister located in the enginecompartment attached to the front right handvalance.When the fuel expands in the fuel tank due totemperature increase it is vented into the bottom ofthe expansion tank, any liquid fuel can be siphonedback into the main tank. Fuel vapour is directed asthe fuel cools through the outlet pipe at the top ofthe expansion tank to the adsorption (charcoal)canister by means of a pipe running along theunderside of the vehicle.A restrictor located in the purge line at the plenumchamber controls purge line flow.The adsorption canister containing activatedcharcoal is used to store fuel vapour from the fueltank. Filter pads are fitted above and below thecharcoal to prevent ingress of foreign matter ofcharcoal into the purge line. Emissions from thefuel tank enter the top of the canister and thepurging air enters at the bottom. The canister ispurged of its vapours by the vacuum generatedwithin the plenum chamber, the vapour beingdrawn into the plenum chamber and burnt with thein-going mixture.KEY TO DIAGRAM1. PCV intake filter2. PCV breather filter1


EMISSION CONTROL


‘. :,:.::.;;;g 1987EMISSION CONTROL.: ,.CATALYTIC CONVERTORSThree catalytic convertors are fitted into the exhaustsystem to reduce carbon monoxide, oxides ofnitrogen and hydrocarbon emissions. The two downpipes from the exhaust manifolds each house anoxygen sensor located forward of the catalyticconvertors.POSITIVE CRANKCASE VENTILATION AIR INTAKEFILTERThe PCV air intake filter is located at the rear of theleft hand rocker cover, beneath the throttle linkagebracket.Remove and RefitThe active constituents of the catalytic device areplatinum and rhodium. In order for the device tofunction correctly, it is necessary to control veryclosely the oxygen concentration in the exhaust gasentering the catalyst. This is achieved by the use ofa fuel control system which continuously monitorsthe oxygen content of the exhaust gas by means ofthe oxygen sensor and adjusts the mixture level toobtain the required oxygen content.Removing1. Pry the filter outer cover upwards to release itfrom its mounting.2. Remove the sponge filter from the cover anddiscard the sponge.‘:.Unleaded fuel must be used on catalyst equippedvehicles, and labels to indicate this are displayed onthe instrument panel and inside the fuel filler flap.The filler neck is designed to accommodateunleaded fuel pump nozzles only./.’ .\.The emission control system fitted to this engine isdesigned to keep emissions within legislated limits,providing the engine is correctly maintained and isin sound mechanical condition.RR 595MRefitting3. Insert a new filter into the filter cover.4. Press the filter onto its mounting until it clipsfirmly into position.3.’. . .


EMISSIONCONTROL1987 rot;;POSITIVE CRANKCASE VENTILATION BREATHERFILTERRemove and RefitRemovingRelease the hose clamp and pull the hose offthe canister.Unscrew the canister and remove it from therocker cover.Remove the large rubber ‘0’ ring and inspectfor deterioration.ADSORPTION (CHARCOAL) CANISTERRemove and Refit .:RemovingDisconnect from the canister:-(i) Canister line to expansion tank(ii) Canister purge lineLoosen the clamp nut screw.Remove the canister.Remove the short hose from the inlet vapourpipe and check that the restrictor is free fromblockages.Visually inspect the condition of the wirescreen within the canister, if in poor condition,replace the whole assembly, if the filter unit isin an acceptable condition, clean as follows.Immerse the canister in a small amount ofsolvent (mineral spirits) and allow time for thesolvent to dissolve or loosen any debris.Remove the canister from the solvent bath andallow to dry in still air.WARNING: DO NOT USE A COMPRESSED AIRLINE TO DRY; CLEAN OR REMOVE ANYREMAINING PARTICLES OF DEBRIS WITHIN THECANISTER AS THIS COULD CAUSE FIRE ORPERSONAL INJURY.Refitting7. If the original canister is being refitted, fit anew ‘0’ ring.8. Screw the canister into the rocker coversecurely - hand tight only.9. Refit the hose and tighten the hose clampsecurely.Refitting5. Secure the canister in the clamp.6. Reverse instructions 1 and 2 above.WARNING: The use of compressed air to cleanan adsorption canister or clear a- blockage in theevaporative system is very dangerous. Anexplosive gas present in a fully saturated canistermay be ignited by the heat generated whencompressed air passes through the canister.J4‘;..:.. . :.


R”d;‘;r; 1987 EMISSION CONTROL,-1 . .,.::._.‘.FUEL EXPANSION TANKRemove and RefitThe fuel expansion tank is located between theright hand rear fender and inner body sideassembly, access to the tank is gained by removingthe rear fender and body corner panel. See Section76 Body, for the removal and refit of the rearfender assembly.WARNING: Ensure all necessary precautions aretaken against the spillage of fuel whendisconnecting the expansion tank hoses.Removing1.2.3.4.5.6.7.8.9.Depressurize the fuel system. (seeDepressurizing procedure in Fuel InjectionSystem-section 19 page 34)Disconnect negative battery terminal.Remove the rear lamp cluster.Remove the wrap around bumper end cap.Remove the rear fender and comer panelassembly.Release the three hose clamps and remove thethree hoses from the expansion tank.Release the hose clamp and remove the hosefrom the float valve located on top of theexpansion tank.Remove the three bolts retaining the bottomof the expansion tank.Lift the trim covering the vehicle tool kit at theright hand side of the rear stowage area togain access to the two expansion tanksecuring bolts located below the rear sideglass and remove the two bolts.10. Remove the tank from the vehicle.11. Remove the short hose connection from thetop vapour hose and check that the restrictorin the hose is free from blockages.12. While the tank is still removed from thevehicle check the operation of thefloat/rollover valve as follows:A. Seal the top two outlet pipes.B. Apply air pressure at 2 p.s.i to thebottom pipe. With the tank in its uprightposition air flow will pass through thevalve. Rotate the tank 90” onto its sideair flow should not pass through thevalve.C. Disconnect the air supply to the tank.With the bottom pipe sealed fill the tankwith mineral spirit, hold the tank in itsupright position, the float valve shouldshut off and prevent fluidpassingthrough the valve.D. If the valve does not operate accordinglywith the above instructions; replace thefloat valve.NOTE: DO NOT remove the float valveunless faulty. if a new valve is fitted ,alwaysfit a new grommet.9ARRZlWEB , CbContinued


l-l 17 EMISSION CONTROL13. Before refitting the tank remove the breatherhose attached to the top of the filler neck,identify filler neck to breather hose end to aidreassembly. Vigourously shake the hose andlisten for valve ball movement; no sound fromthe valve-replace the hose assembly.Refitting14. Refit the expansion tank ensuring that all hoseand pipe connections are secure and that allhose clamps are securely tightened.Remove and RefitRemoving1. Pull the two flexible hoses from the delay unit.2. Remove the unit from its retaining clip andwithdraw it from the engine compartment.,’VACUUM DELAY VALVEThe coloured side of the vacuum delay valveshould always be fitted to the hose from thedistributor.Test: Check Valve Air Flow1. Attach a 10.00 + .250 cu.inch vacuum tank tothe coloured side of the valve.2. Expose the black side to atmospheric pressure.3. Expected result: The time required for thevacuum to drop from minus 20 inch Hg tominus 2 inch Hg will be 0.5 secondsmaximum.4. Vacuum recovery air flow: Attach a 22.75 + .5cu.inch vacuum tank to the black side of thevalve.5. Expose the coloured side to atmosphericpressure.6. Expected result: The time required for thevacuum to drop from 16 inch Hg to 8 inch Hgwill be 240 to 360 seconds.Test: External leakage Check1. Seal the coloured side of the valve and attacha short flexible pipe to the other end.2. Submerge the valve in water and orally blowthrough the valve.3. If any external leakage is noticeable, fit a newvalve.If the delay valve does not comply with any ofthe test results, replace the unit.Refitting3. Reverse the removal instructions ensuring thatthe coloured side of the valve is fitted to thelonger hose from the distributor.: I,’6.‘.’. . . .


;“d;‘;r; 1987EMISSION CONTROL::,. .LAMBDA (OXYGEN) SENSORRemove and RefitThe removal of the sensors from the exhaustsystem must only be carried out when the engine iscold.Removing1. Disconnect the battery negative lead.2. Disconnect the electrical plugs from thesensors.3. Unscrew and remove the sensors from thetwo exhaust downpipes.Refitting4. Coat the threads of the sensor with anti-seizecompound.CAUTION: To ensure that the efficiency ofthe sensor is not impaired. DO NOT allowanti-seize compound to come into contactwith sensor nose.5. Screw in the sensor and tighten to the correcttorque using special tool LST134.6. Connect the electrical plugs and battery lead.REVISED: MARCH 90 7 ‘.‘1_:..


17 EMISSION CONTROL1987 PO;;;EMISSION LABEL:..A vehicle Emission Control information label isattached to the hood locking platform locatedabove the right hand headlamp assembly. The labelgives Engine Tune Details to ensure that correctEmissions Levels are achieved. The label is fitted tocomply with lJ.S Federal and State of CaliforniaRegulations and should not be removed from itslocation within the vehicle.‘.Example of Label - 1987 Model YearLAND ROVER U.K. LTD.- VEHICLE EMISSION CONTROL -INFORMATION.ENGINE FAMILYzHLR3.5T5FRR7DISPLACEMENT ~215.3 CU INSEVAP FAMILYRAF1EX.EM.CONTROL SYSTEM :EFI:TWC/EGS(P)IDLE MIXTURE ADJUSTMENTNO MEANS OF ADJUSTMENT - CLOSED LOOP CONTROL.IDLE SPEED ADJUSTMENTENGlNE HAS IDLE SPEED CONTROL-NO ADJUSTMENT NORMALLY REOUIRED.REFER TO WORKSHOP MANUAL.,_( .:...’. .IGNITION TIMING 6O 6.T.D.C AT BELOW 800 r.p mWITH DISTRIBUTORVACUUM UNITDISCONNECTEDY IDLE SPEED 865-735 r.p.m5 SPARK PLUG GAP 0.033-0.03&n.: ‘.LRR1886ETHIS VEHICLE CONFORMS TO U.S. E.P.A. AND STATE OF CALIFORNIA REGULATIONS APPLICABLETO 1987 MODEL YEAR NEW LIGHT DUTY TRUCKS.(.‘.Example of Label - 1988 Model Year,I0zD .4 .LAND ROVER U.K. LTDG?m. ,fVEHICLE EMISSION CONTROLINFORMATION.IDLE MIXNRE ADJUSTMENT.NO MEANS OF ADJUSTMENT - CLOSED LOOP CONTROL.IDLE SPEED ADJUSTMENT.‘.ENGINE FAMILY :JLR3STSFRRODISPLACEMENT:2 15.3 CU INS.EVAP FAMlLY:RAFIEX.EM.CONTROL SYSTEM :EFI:TWC/EGS(P)ENQINE HAS tDLE SPEED CONTROL-NO ADJUSTMENT NORMALLY REWJREDREFER TO WORKSHOP MANUAL.IGNITION TIMING 6O E.T.D.C AT BELOW 600 r.p.mWITH DISTRIBUTORVACUUM UNITDISCONNECTEDOBD EXEWTIDLE SPEED 665-735 r.p.mSPARK PLUG GAP 0 033-0.03tm.”.‘. ’‘.THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLETO 1988 MODEL YEAR NEW LIGHT DUTY TFKJCKS..RR2287E‘\I::‘..”.’..,._’‘.’ .“..,: .:.,:: . ...:8 REVISED: MARCH 90


R”^d;‘;r; 1989-91EMISSION CONTROL I17 1,:.: ,,‘.ExamDIe of Label - 1989 Model YearIGEB‘ILAND ROVER LTD.VEHICLE EMISSION CONTROLINFORMATION.ENGINE FAMILY .KLR3.9TSFSS4DISPLACEMENT :240 CU HS.EVAP FAMILYRAFIEX.EM.CONTROL SYSTEM :FI:2-TWC/2-HoSI4!!iiD., IDLE MIXTURE ADJUSTMENT.NO MEANS OF ADJUSTMENT - CLOSED LOOP CONTROLIME SPEED ADJUSTMENT.ENGlNE HAS IDLE SPEED CONTRM-NO ADJUSTMENT NORMALLY REOUIRED.REFER TO WORKSHOP MANUAL.IGNITION TIMING EI” B.T.D.C AT BELOW 600 mm.WITH DISTRIBUTORW\CUUM UNITcDISCONNECTED%Z IDLE SPEED 665-735 r.p.m.2 SPARK PLUG GAP 0.033-@.03&nDBD EXEMPTRFrc3llETHIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIATO 1989 MODEL YEAR NEW LIGHT DUTY TRUCKS.REGULATIONS APPLICABLE. . . . . .IExample of Label - 1990 Model YearcaDLAND ROVER LTD. 3‘, ‘,abIMPORTANT VEHICLEINFORMATIONIDLE SPEED ADJUSTMENTENGINE HAS IDLE SPEED CONTROLNO ADJUSTMENT NORMALLY REOUIRED.4ENGINE FAMILY:LLR3.9T5FSS5DISPLACEMENT:241 CU INSEVAP. FAMILY :RAF 1EX.EM.CONTROL SYSTEM :MPl :2-TWCIZ HOZSIREFER TO WORKSHOP MANUAL.NO OTHER ADJUSTMENTS NEEDED.IGNITION TIMING 6O + 1 o 6 T.D.C AT BELOW 600 r.p.mWITH DISTRIBUTORVACUUM UNITDISCONNECTEDIIDLE SPEED 665.735 r.p.m.SPARK PLUG GAP 0.033.0.036in 3T39T5FSSATHIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE\ TO 1990 MODEL YEAR NEW LIGHT DUTY TRUCKS.RR2698EExample of Label - 1991 Model Year‘. :;e \ROVER GROUP LIMITED-IMPORTANT VEHICLE INFCIMATION- RANGE ROVER.’.ENGINE FAMILY :MLR3,9TSFSS6DISPLACEMENT:241 CU INS 13.9 LITERSEVAP.FAMILY:RBFIEXHAUST EMISSIONCONTROLSYSTEM:MPI:2.TWC/2-H02S_ - - - - - - - _ _ - - - _ _ - - - _ - - .39T5FSSAI 1TUNE UP SPECIFICATIONSCATALYSTTUNE UP CONDITIONS :.ENGINE AT NORMAL OPERATING TEMPERATURETRANSMISSION IN PARKIDLE SPEED - 665-735 rpmENGINE HAS IDLE SPEED CONTROLNO ADJUSTMENT NORMALLY REOUIREDSPARK PL;G GAP . 0.033-0.036 InchIGNITION TIMING - 6’ : 1’ BTDC AT BELOW 600 rpmWITH DISTRIBUTOR VACUUM UNIT DISCONNECTEDNO OTHER ADJUSTMENTS NEEDEDTHIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONSAPPLICABLE TO 1991 MODEL YEAR NEW LIGHT DUTY TRUCKS.RR 2935EREVISED: SEPT. 90 9


-l 17 EMISSION CONTROLEMISSION CONTROL.:1989 model year vehicles incorporate evaporativeemission control by a new charcoal canister withsolenoid operated purge valve.The charcoal canister adsorbs and stores the fuelvapor that is emitted from the fuel tank when theengine is not running. The vapor is purged from thecanister by outside air drawn through an orifice atthe bottom of the canister by the application ofmanifold vacuum to the top.A solenoid operated valve controls purging of thecanister. The valve is controlled by the fuel injectionECU to ensure that purge normally takes place atengine speeds above idle and when the vehicle isin motion. The rate of purge will depend on enginespeed, road speed and throttle position.Purge valve fault diagnosis is included in EngineFault Diagnosis - Section 12.Testing purge valve operation is included in FuelInjection Test Procedure - Section 19, Tests 9 and70.NOTE: If crimped hoses are removed it isessential that they are recrimped on reassemblyto ensure a leak free joint.IVacuum delay valveThe vacuum delay valve is not fitted to 3.9 litremodels.10 REVISED: SEPT. 90


‘...:I :.:‘.’KAlYClCROVER 1989-91 EMISSION CONTROL. . . :,.,I‘.‘, Charcoal canisterCharcoalcanister:.:.’:


EVAPORATIVE CONTROL SYSTEM - 1991 modelyear2 . . . . . .z \; :: : :ADDITION: SEPT. 90‘..:


EMISSION CONTROL I17 1Evaporative emission control system - 1991model yearThe system is designed to prevent harmful fuelvapor from escaping to the atmosphere. The systemconsists of a new vapor separator tank connectedto the fuel tank, and located between the bodyinner and outer panels on the right hand side ofthe vehicle near the rear wheel arch. An adsorptioncanister, containing activated charcoal, is positionedin the engine compartment attached to the frontright hand fender valance. The two components areconnected by a pipe running the length of thechassis.A pressure relief valve is fitted in the hose open toatmosphere, which would act as a safety valveshould a build-up of pressure occur in the system,lor example if a hose became blocked or kinked.The volume of vapor emitted, in such an instance,would be acceptable.A pressure relief valve is also fitted in the hose tothe adsorption canister and releases vapor to thecanister when the pressure in the separator reachesbetween .75 and 1.0 psi.In the top of the separator a shut-off valve isincorporated in the vapor exit port to prevent thepossible presence of any liquid fuel beingtransmitted to the adsorption canister should thevehicle roll over.The adsorption canister, which is connected byhose to the plenum chamber, adsorbs and storesthe fuel vapor from the fuel tank while the engineis not running. The vapor is purged from thecanister by air drawn through an orifice in the baseof the canister and by the influence of vacuum atthe top. The vapor drawn into the plenum chamberthrough a solenoid operated purge valve is finallyburnt in the combustion chambers.ST2666MLST2665MA Pressure relief to atmosphere.B From fuel tank to separator.C To adsorption canister.D Pressure relief valve.E Pressure relief valve.F Shut-off valve.c “Speed Fit” connectors.The purge valve, which is attached to theadsorption canister support bracket, is controlled bythe fuel injection E.C.U. which determines the mostemission acceptable time at which purging shouldtake place. This will normally be at engine speedsabove idle and when the-vehicle is in motion. Asignal from the E.C.U. to the purge valve operatesthe solenoid and opens the valve to purge thecanister of fuel vapor.Ji..1:.ADDITION: SEPT. 90 13 :


EMISSION CONTROL1989-91 ;;^o”v‘;r;VAPOR SEPARATORRemoveWARNING: Ensure that ail necessary precautionsare taken against fuel spillage and fuel vapor toprevent fire or explosion.1. Disconnect the battery negative terminal.2. Working from beneath the vehicle, disconnectthe evaporative control pipes from the greenend of the “speedfit” connectors. To achievethis, manufacture a suitable tool with a forkedend to fit into the two slots in the end of theconnector as shown in the illustration below.Press down on the collet and while depressedpull the pipe from the connector.NOTE: While the pressure relief valves arerenewable, the shut-off valve in the top ofthe separator is only available completewith a new separator assembly.Fitting vapor separator.5. Fit the separator and pipes into the vehicleside panel, if necessary using a new seal. Fitthe self adhesive side to the separator. Securewith the four screws.6. From beneath the vehicle, fit the pipes fromthe separator to the connectors. Push eachpipe into the corresponding connector as faras it will go so that it is locked by the collet.Check that the pipes are free and not trappedor kinked. Secure the pipes to the under bodyclips.:3. Remove the four screws securing the vaporseparator support plate to the body panelsituated in the right hand side of the loadspace.4. Withdraw the separator and pressure reliefvalves from the vehicle.-i1 4 ADDITION: SEPT. 90


EMISSION CONTROL Ii 7 1TESTING EVAPORATIVE EMISSION CONTROL 5.’ .’:, The following pressure test procedure is intendedto provide a method for ensuring that the systemdoes not leak excessively and will effectively controlevaporative emissions. 6.Equipment required.Nitrogen cylinder (compressed air may be used topressure the system when there has NEVER beenfuel present in the fuel or evaporative controlsystems).7.Measure the pressure drop within a period of2 minutes 30 seconds. If the drop is greaterthan 2.5 inches of water the system has failedthe test. Note that a fully sealed system willshow a slight increase in pressure.Should the system fail the test, maintain thepressure in the system and apply a soapsolution round all the joints and connectionsuntil bubbles appear to reveal the source ofthe leak.Repeat the test and if successful, dismantle thetest equipment and reconnect the pipe to theadsorption canister.Water manometer (0 - 30” H20 or more).Pipework and a “T” piece.Method.1. Ensure that there is at least two gallons of fuelin the fuel tank unless there has never beenany fuel in the system.2. Disconnect, at the adsorption canister, thepipe to the vapor separator.3. Connect this pipe to the nitrogen cylinder andthe water manometer using the “T” piece.4. Pressurize the system to between 26.5 and27.5 inches of water, allow the reading tostabilize, then turn off the nitrogen supply.JADDITION: SEPT. 90 15


J: ‘I


;;“d;;l; 1987CRUISE CONTROLCRUISE CONTROL SYSTEM-HELLA CR66ROAD SPEED TRANSDUCER,’ -;CAUTION: DO NOT ENGAGE CRUISE CONTROLWHEN THE VEHICLE IS BEING USED IN LOWTRANSFER GEARS.DESCRIPTIONThe Cruise Control system consists ofelectro-mechanical devices, and comprises of thefollowing components.The Road Speed Transducer is fitted between theupper and lower speedometer cables. It is mountedon a bracket located on the left hand chassis sidemember adjacent to the rear engine mounting. Thetransducer provides road speed data to the E.C.U.The cruise control system cannot be engaged untilthe road speed exceeds 28 mph (45 km/h), thesystem will automatically disengage at a road speedof 26 mph (42 km/h)..‘,’ELECTRONIC CONTROL UNIT (ECU)The electronic control unit is located behind thelower dash panel attached to the underside of theinstrument binnacle. The Microprocessor basedE.C.U. evaluates the signals provided by the drivercontrols, brake pedal switch and the road speedtransducer, and activates the vacuum pump in anappropriate manner. The E.C.U. also has a memoryfunction for set speed storage.DRIVER OPERATED SWITCHESThe main cruise control switch is located in theauxiliary switch panel and activates the cruisecontrol system. The steering wheel switches provide‘set/accelerate’ and ‘resume/decelerate features.These switches provide the interface between driverand cruise control system.BRAKE PEDAL SWITCHThe Brake Pedal Switch is located under the lowerdash attached to the brake pedal mounting bracket.The switch provides for fast disengagement of thecruise control system and rapid return of thethrottle levers to the idle position when the brakepedal is applied.VACUUM PUMPThe Vacuum Pump is located in the enginecompartment attached to the left hand valance. Thevacuum pump is energised when the main controlpanel is operated, and is actuated by the steeringwheel and brake pedal switches. The pumpprovides a vacuum source to the cruise controlactuator at the throttle levers. A control valve in thepump provides for steady increase of road speed orrapid purge of the system when the brake pedal isapplied.ACTUATORThe Actuator is located in the engine compartmentand is bolted to the throttle lever bracketry. Theactuator provides the servo mechanism linkbetween the cruise control system and throttlelinkage and is operated by vacuum from thevacuum pump.REVISED: SEPT. 90 1


FAULTDIAGNOSISif the system does not function the following checks must be carried out.Fuse A6 - intactVacuum hoses - not split or disconnectedActuator - diaphragm rupturedVacuum Pump - motor operationalBrake Switch - faulty or out of adjustmentSpeed Transducer - faulty - check operation of unitElectrical Leads - loose connections - faulty leadsStop Lamp Bulbs - both bulbs faulty - replace: Fuse 13 intact.PRELIMINARY CHECKS PRIOR TO TESTING1. Ignition switch “ON”.2. Fuse A-6 “OK”.3. Cruise Control master switch “ON”.4. Minimum 12.OV (Battery) available.CRUISE CONTROL OPERATIONAL CHECKSAll system testing may be performed with a multi-meter and jumper wire at the ECU connector.Sequence of connections viewed on harness plug connector to ECUColour coding/function of wiring to plug:TERMINAL NO. COLOUR FUNCTION1. White/Yellow2. Red/White3. Purple/Green4. Black/Red5. Yellow6. Blue/White7. Black/Yellow0. BlackMain power from master switch12~ + from set switch (when pressed)Ground via vent valve switch and brake light filamentsTo vacuum pump motorTo speed transducerIN + from resume switch (when pressed)To vacuum pump solenoid valveECU ground2REVISED: SEPT. 90


;;“d;;ll; 1987CRUISECONTROLTESTPROCEDUREVolt Meter Connections Specified Result Possible Problem if Results not as Specified1. Terminal 1 and ground2. Terminal 1 and 83. Terminal 1 and 34. Terminal 6 and 8(press resume)5. Terminal 2 and 8(press set)6. Terminaj 5 and 8 -Rotate left-rearwheel, right-rearwheel remains ongroundBatteryBatterBatteryBatteryBatteryvoltagevoltagevoltagevoltagevoltageO-12\'fluctuating6 times perrevolutionFuse, wiring, master switchPoor groundBrake light ground, vent valve switch, wiring,brake light bulbsWiring, resume switch, cassetteWiring, set switch cassetteWiring, speed transducerVACUUM SYSTEM - VACUUM PUMP TESTSConnect a jumper wire between: Terminal 4 and 8 & 7 and 8 - vacuum pump must run and fully retractactivator diaphragm. Remove jumper from Terminal 4 (7 & 8 still connected). Pump stops, but diaphragmremains retracted. Remove jumper from Terminal 7 - diaphragm extends.If results are not as specified check: vacuum hose/connections,pump, vacuum pump.vent valve/adjustment, wiring to vacuum. . 1-‘_ROAD TESTCAUTION: DO NOT ENGAGE CRUISE CONTROLWHEN THE VEHICLE IS BEING USED IN LOWTRANSFER GEARSWARNING: The use of cruise control is notrecommended on winding, snow covered orslippery roads or in heavy traffic conditionswhere a constant speed cannot be maintained.1. Start the engine and depress the main controlswitch to actuate the cruise control system.Accelerate to approximately 30 mph (50 km/h)and operate the ‘set/act’ switch, immediatelyrelease the switch, remove the foot from theaccelerator pedal, the vehicle should maintainthe speed at which the ‘settacc’ switch wasoperated.2. Operate the ‘set/act’ switch and hold at thatposition, the vehicle should acceleratesmoothly until the switch is released. Thevehicle should now maintain the new speed atwhich the ‘set/act’ switch was released.3. Apply the ‘res/decell switch while vehicle is incruise control mode, the cruise control shoulddisengage. Slow to approximately 35 mph (55km/h), operate the ‘res/decel’ switch,immediately release the switch and remove thefoot from the accelerator, the vehicle shouldsmoothly accelerate to the previously setspeed. Increase the speed using theaccelerator pedal and release the pedal, thevehicle should return to the previously setspeed.4. Operate the brake pedal, the cruise controlsystem should immediately disengagereturning the vehicle to driver control at theaccelerator pedal. Operate ‘res/decel’ switch,vehicle should accelerate to previouslymemorised set speed without driver operationof the accelerator pedal.5. Operate ‘res/decel’ switch and allow vehicleto decelerate to below 26 mph (42 km/h).Operate kes/decel’ switch, cruise controlsystem should remain disengaged.6. Operate the ‘set/accl switch below 28 mph(45 km/h), the cruise control system shouldremain disengaged. Accelerate, using theaccelerator pedal to above 28 mph (45 km/h),operate ‘res/decel’ switch, and remove thefoot from the accelerator pedal, vehicle shouldsmoothly adjust to the previously memorisedspeed.7. Depress the main control switch in theauxiliary switch panel, cruise control systemshould immediately disengage and erase thepreviously set speed from the E.C.U. memor)‘.i:._:. .’REVISED: SEPT. SO3, .‘I.


-l t9 CRUISE CONTROL1987 “R”d;;l;CRUISE CONTROL-circuit diagram1. Electronic cruise control unit.2. Vacuum pump.3. Brake switch/vent valve.4. Stop lamps.5. Brake switch.6. Steering wheel set and reset switches.7. Ignition supply to stop lamp circuit.8. Cruise control switch - auxiliary switch panel.9. Fuse A6-auxiliary fuse panel (7.5A).10. 12V+ supply to speed transducer.11. Speed transducer.12. ignition load relay - item 1 main circuitdiagram.13. Battery feed.14. Cruise control harness multi-plug pinidentification.15. Ignition switch - item 8 main circuit diagram___ Denotes existing main cable circuit.Cable Colour Code - The last letter of a colour code denotes the tracer.:W. WhiteY. YellowC. GreenP. PurpleU. Blue R. RedB. Black S. Crey5678‘,’RR2377EEARLY MODELS - Wiring identification‘..:Illustration RR225BE shows the current cruise.control wiring condition and colour coding fromthe steering wheel switches to the cassette plug,earlier models were colour coded rjfferently andcan be identified as follows:-.,::,Latest condition Early conditionRed/whiteBlue/whiteGrey/yellowGreen/redGreen/blackRed/blue?. ‘. ‘,‘.4 REVISED: SEPT. ~0.,.;


R”o;; 1987CRUISE CONTROL 119 1.’ . .BRAKE SWITCH-VENT VALVERemove and refitRemoving1.2.3.4.5.6.i.Disconnect the battery negative terminal.Remove the six screws securing the lowerdash panel.Lower the panel and disconnect the rheostatswitch multi-plug and remove the warninglamp control unit from the retaining clip.Withdraw the lower dash panel from thevehicle.Disconnect the electrical multi-plug from thebrake switch/vent valve.Pull the hose from the switch.Unscrew the adjusting nut and withdraw theswitch.DRIVER OPERATED CRUISE CONTROLSWITCHES-STEERING WHEELNOTE: MAIN CONTROL SWITCH. The removaland refit of the main control switch and bulbreplacement is included in the Electrical Section86, as part of the auxiliary switch panel removal.Remove and refitRemoving1.2.3.4.5.6.7Disconnect the battery negative terminal.Carefully pry the centre trim pad off thesteering wheel.Disconnect the electrical multi-plug located inthe small opening below the steering wheelretaining nut.Carefully pry the switch(es) out of the steeringwheel spoke(s).Release the small switch b&ton from theopening within the spoke(s).Carefully pull the switch and electrical leadsthrough the spoke until access is gained tothe electrical connections beneath the switch.Disconnect the electrical leads from the switchand withdraw the switch(es).;i . .Refitting8. Refit the switch and fit the adjusting nut.Adjust the valve to provide a clearance of 1.0mm (0.039 in) between the valve body andInside shoulder of the contact button.9 Fit the hose and multi-plug ensuring that the)are secure.IO. Reverse the remaining removal instructions.Refitting -8. Reverse the removal procedure ensuring thatthe electrical leads are fitted securely.li!,c,-.‘,,REVISED: SEPT. 905:i


SPIRAL CASSElTEThe spiral cassette is located below the steeringwheel encased in the steering column shroud.Access to the unit is gained by removing theaforementioned items.Carefully ease the two halves of the shroudapart until access is gained to the electricalmulti-plug on the bottom half of the cassetteand disconnect the multi-plug.Withdraw the cassette from the steeringcolumn..,I -1, .’4NOTE: To enable the steering wheel to berefitted in its correct radial position, ensure thefront road wheels are in the straight aheadposition.Remove and refitRemovingService Tools:18G 1014 Steering wheel remover18G 1014-2 Adaptor pins1.2.3.Disconnect the battery negative terminal.Remove the steering wheel centre trim panel.Disconnect the electrical multi-plug located inthe small opening in the centre of the steeringwheel.4. Remove the steering wheel seckng nut andserrated washer, using service tool 18G 1014and adaptor pins, withdraw the steering wheel.CAUTION:Appiy adhesive tape to the upper andlower halves of the cassette to prevent the upperhalf of the spiral cassette rotating after thesteering wheel is removed. Failure to do this willresult in damage to the flexible tape inside thecassette.5. Remove the six lower fixings securing thesteering column shroud.6. Release either the left hand or right handfixing securing the top of the shroud.RR2041ERefitting9.10.Remove the adhesive tape retaining the upperand lower halves of the spiral cassette.NOTE: Ensure that the two driving pegs onthe spiral cassette locate in the two holeson the underside of the steering wheelbefore refitting the steering wheel securingnut.Reverse the removal instructions, ensuring thatall electrical leads located beneath the steeringcolumn shroud are arranged so they do notbecome trapped between the shroud matingfaces.J6 REVISED: SEPT. 90


R”o”v’i;; 1987CRUISE CONTROLACTUATOR..‘. NOTE: The actuator itself is not aserviceable item, in the event of failure ordamage fit a new unit.Remove and refitRemoving1. Disconnect the battery negative terminal.2. Pull the short rubber elbow from the actuator.3. Remove the nut securing the actuator to thethrottle bracketry.4. Detach the actuator from the bracket andmaneuver the actuator operating link off thethrottle lever.5. Withdraw the actuator from the enginecompartment.Adjust the linkRemove the link from the actuator.Rotate the socket joint on the actuator linkclockwise or counter-clockwise to decrease orincrease the operating length of the link.Refit the link to the actuator and recheck theclearance between the link and lever.With the trottle fully open, check that a gap ofat least 3mm (l/8”) exists between the side ofthe actuator link (“A” in illustration) and theside of the small spring which connects theinner throttle level to the outer throttle lever(“B” in illustration). Realign the actuator link bybending to achieve the correct gap if it is lessthan 3mm. Recheck the clearance at closedthrottle/open throttle and check that theactuator link slides smoothly in the groove ofthe throttle lever.Refitting6.7.Inspect the rubber diaphragm for condition. Fita new Actuator assembly if the diaphragm is inpoor condition.Reverse the removal procedure, ensuring thatthe hook is fitted uppermostACTUATOR LINK-SElTINGNOTE: The setting procedure outlined is atminimum throttle condition only._:,_.’,’ -1. Ensure ignition is switched ‘OFF’.2. Check the clearance between the inside edgeof the actuator link and recessed diameter ofthe throttle lever. Clearance should be 0.2 to2.0 mm (0.008 to 0.080 in).Rft2316E. -REVISED: SEPT. 90 71’


-l 19 CRUISE CONTROL1987 KANCltROVERVACUUM PUMPNOTE: The vacuum pump is not a serviceableitem, in the event of failure fit a new unit.Remove and refitRemovingELECTRONIC CONTROL UNIT (ECU)- CRUISE CONTROL.The cruise control electronic control unit (ECU) islocated behind the lower dash panel below thesteering column, and is attached to the undersideof the instrument binnacle, access to the ECU isgained by removing the lower dash panel.; ::: \.’ ;‘.,1. Disconnect the battery negative terminal.2. Disconnect the multi-plug from the top of thevacuum pump.3. Disconnect the vacuum feed hose from thevacuum pump.4. Withdraw the three vacuum pump rubbermountings from the left hand valance/innerfender assembly.Remove and refitRemoving1.2.3.4.5.6.Disconnect the battery negative terminal.Remove the six screws retaining the lowerdash panel.Lower the panel and disconnect the electricalmulti-plug from the rheostat switch and detachthe warning lamp control unit from theretaining clip.Withdraw the lower dash panel from thevehicle.Remove the two fixings to enable the ECU tobe lowered to give access to the electricalmulti-plug.Disconnect the multi-plug to the ECU, andremove the unit from the vehicle.‘15. Withdraw the pump from the engineRefittingcompartment.6. Reverse the removal procedure ensuring thatthe hose and electrical connections are secure.Refitting7. Reverse the removal instructions ensuring thatthe electrical multi-plug is securelyreconnected.J.’1:.8 REVISED: SEPT. 90‘, .:’ ,:


CRUISE CONTROL - Circuit diagram- 1989 Model Year1.2.3.4.5.6.7.8.9.Electronic cruise control unitVacuum pumpBrake switch/vent valveStop lampsBrake switchSteering wheel set and reset switchesIgnition supply to stop lamp circuitCruise control switch-auxilian/ switch panelFuse Ab-auxiliary fuse panel (7.5A)10.11.12.13.14.15.16.17.__-1X + supply to transducerSpeed transducerIgnition load relay-item 1 main circuit diagramBattery feedCruise control harness multi-plug identificationIgnition switch-item 8 main circuit diagramRelay - neutral lockoutStart inhibit switchDenotes exiting main cable circuitCable colour code-the last letter of a colour code denotes the tracer.W White ’ G Green U Blue R RedY Yellow P Purple B Black S GreyN BrownIIWY SETIACC 6,RR2473E2ECU multi-plug identification.‘yTERMINALNO.1.2.3.4.5.6:7.8.COLOURWhite/YellowRedMhitePurple/GreenBlack/RedYellowBlue/WhiteBlack/YellowBlackFUNCTIONMain power from master switch12\’ + from set switch (when pressed)Ground via vent valve switch, brake light filaments. neutral relayTo vacuum pump motorTo speed transducer13’ + from resume switch (when pressed)To vacuum pump solenoid valveECU groundADDITION: SEPT. 88/REVISED: SEPT. 90 9,’ :.:’,‘.‘. . ...:


1\rw*uLilg8’ ROVERNEUTRAL LOCKOUT RELAY-CRUISE CONTROL1989 Model Year vehicles have a relay in theelectrical circuit which will disengage the cruisecontrol system if neutral, or park, is selected in themain gearbox, when the system is engaged.The relay is located under the rear of the front righthand seat adjacent to the emission maintenancereminder. Access to the unit is gained through theopening at the bottom of the seat when the seat isin its fully forward position.Remove and refitRemoving1. Ensure the seat is adjusted fully forward.2. Disconnect the battery negative terminal3. Pull the relay from the terminal block.Refitting4. Reverse the removal instructions.JADDITION: SEPT. IS/REVISED: SEPT. 90


KANCItROVER 1989-90 CRUISE CONTROL 1 it 1FAULT DIAGNOSISIf the system does not function the following checks must be carried out,Fuse A6 - intact tC5 1990 Model Year).Vacuum hoses - not split or disconnectedActuator - diaphragm rupturedVacuum Pump - motor operationalBrake Switch - faulty or out of adjustmentSpeed Transducer - faulty - check operation of unitElectrical Leads - loose connections - faulty leadsStop Lamp Bulbs - both bulbs faulty - replace: Fuse 13 intact, (A5 1990 Model Year)Neutral Relay - operational.PRELIMINARY CHECKS PRIOR TO TESTING1. Ignition switch “ON”.2. Fuse A-6 “OK”.3. Cruise Control master switch “ON”.4. Shift lever in ‘D’.5. Minimum 12.OV (Battery) available.CRUISE CONTROL OPERATIONAL CHECKSAll system testing may be performed with a multi-meter and jumper wire at the ECU connector.TESTPROCEDUREVolt Meter ConnectionsSpecified ResultPossible Problem if Results not as Specified1. Terminal 1 and ground Battery voltage2. Terminal 1 and 8 Batter voltage3. Terminal 1 and 3 Battery voltage4. Terminal 6 and 8 Battery voltage(press resume)5. Terminal 2 and 8 Battery voltage(press set)6. Terminal 5 and 8 - o-12vRotate left-rearfluctuatingwheel, right-rear6 times perwheel remains onrevolutiongroundFuse, wiring, master switchPoor groundBrake light ground, vent valve switch, wiring,brake light bulbsWiring, resume switch, cassetteWiring, set switch cassetteWiring, speed transducerNOTE: Complete test procedure by carrying out the Vacuum System Test and Road Test procedure -see page 3, Section 19 - Cruise Control.ADDITION: SEPT. 88 / REVISED: SEPT. 90 111.‘. .’


. .CRUISE CONTROLCRUISE CONTROL - Circuit diagram. 1990 Model Year onwards1. Electronic cruise control unit2. Vacuum pump3. Brake switch/vent valve4. Stop lamps5. Brake switch6. Steering wheel set and reset switches7. Fuse AS8. Cruise control switch-auxiliary panel9. Fuse C5 (lOA)IO. I 2~ + supply to transducer1989-90 k”i;;‘ir;11. Speed transducer12. ignition load relay-item 1 main circuit diagram13. Battery feed14. Cruise control harness multi-plug identification15. Ignition switch-item 8 main circuit diagram16. Relay - neutral lockout17. Start inhibit switch18. Diode---Denotes exiting main cable circuit,.,. \. ‘!Cable clour code the last letter of a colour code denotes the tracer.W White G Green U Blue R RedY Yellow P Purple 6 Black S GreyN Brown,IRR2938EECU multi-plug identification,,.-:’.’‘,‘.TERMINALNO.1.2.3.4.5.6.7.8.COLOURWhite/YellowRedWhitePurple/GreenBlack/RedYellowBlueM’hiteBlack/YellowBlackFUNCTIONMain power from master switrh12~ + from set switch (when pressed)Ground via vent valve switch, brake light filaments. neutral relayTo vacuum pump motorTCJ speed transducerIN + from resume switch (when pressed)TO vacuum pump solenoid valveECU ground‘1.‘.‘.12 ADDITION: SEPT. 89 / REVISED: SEPT. 90‘7.’,’ .:.‘: ,:.;


;;^d;‘;r; 1987FUEL INJECTION SYSTEM 119 1r U. wRR1752EUi I ““IFUEL INJECTION - Circuit Diagram1. 40 way connector to Electronic Control Unit(ECU).2. Lambda sensor (left side - bank A).3. Lambda sensor (right side - bank 8).4. By-pass air valve (stepper motor) (fast idle).5. Lambda sensor screened ground.6. Fuse 18 - main fuse panel.7. Inertia switch.8. Fuel pump.9. Ignition switch.10. Speed transducer (road speed input).7 1. Neutral switch (automatic gearbox) (loadinput).12. Pick-up point-air conditioning circuit (loadinput).13. Battery.14. Diagnostic plug.15. In-line resistor.16. Coil/-ve (engine RPM input).17. Coolant temperature thermistor (sensor)(input).18. Fuel temperature thermistor (sensor) (input).19. Throttle potentiometer.20. Air flow sensor.21. Fuel pump relay.22. Main relay.23. Injectors-l to 8.24. Pick-up point E.F.I. warninasymbol (instrumentbinnacle).= = = Denotes screened ground.NOTE: Reference to left and right side is made when viewing vehicle from rear.Cable colour codeB Black G Green R RedU Blue 0 Orange M’ WhiteN Brown P Purple Y YellowSKLGCreyPinkLight greenThe last letter of a colour code denotes the tracer.REVISED: JULY 881 :,:.:;


l-l 19 FUEL INJECTION SYSTEM1987 rot;;FWL RCOULATOR141 RCA1 OF ENOINELECU AND RELAY8UNDER RIGHT FRONTOEATF:lJEL FILTER ON CHAlllll#FUEL WYP111 FUEL TANAa lNJcc10nsFOR ENONEIROAO OFEED WUtTIIANOOUCERON CNAIOWFUEL TEYFEIIATURE• EN10RliNOiNE FULL RAILA-A1111 IV’cA1I VALVEREAR OF ENOWE BAVCOOLANT tEYPERATU(IE• LNIOR FRONT OF ENOM\ .:-.‘i..J /,.PTWROTTLE FOTENTIOYETEFRONT OFTHROTTLE VALVEIRIHOT WIG ARFLOW8ENaoR FRONT LEFT• EIE OF LNONE • AVlONRlON COLLEFT IDE OF ENWIE • AV. .!RR2178E2 REVISED: JULY 88‘,‘, ., ,. :


ggf;i 1987FUEL INJECTION SYSTEM 119 1INTRODUCTIONThe Electronic Fuel injection system provides areliable and efficient microprocessor controlled fuelmanagement system.The function of the system is to supply the exactamount of fuel directly into the inlet manifoldaccording to the prevailing engine operatingconditions.To monitor these conditions, various sensors arefitted to the engine to measure engine parameters.Data from the sensors is received by the ElectronicControl Unit (E.C.U.), the E.C.U. will thendetermine the exact amount of fuel required at anycondition.The E.C.U. having received data from the sensorsproduces pulses, the length of which will determinethe simultaneous open time of each bank ofinjectors in turn, which will govern the amount offuel injected.DESCRIPTIONELECTRONIC CONTROL UNIT-ECUThe Electronic Fuel Injection system is controlled bythe E.C.U. which is located under the front righthand seat. The control unit is a microprocessor withintegrated circuits and components mounted onprinted circuit boards. The E.C.U. is connected tothe main harness by a 40 pin plug.INJECTORSThe eight fuel injectors are fitted between thepressurized fuel rail and inlet manifold. Each injectorcomprises a solenoid operated needle valve with amovable plunger rigidly attached to the nozzlevalve. When the solenoid is energized the plungeris attracted off its seat and allows pressurized fuelinto the intake manifold.ENGINE COOLANT TEMPERATURE THERMISTOR(SENSOR)The coolant thermistor (sensor) is located by thefront left hand branch of the intake manifold. Thethermistor provides engine coolant information tothe E.C.U. The E.C.U. on receiving the signal fromthe thermistor will lengthen slightly the time thatthe injectors are open, and reducing this time asthe engine reaches normal operating temperature.FUEL TEMPERATURE THERMISTOR (SENSOR)The fuel temperature thermistor (sensor) is locatedin the fuel rail forward of the ram housing. Thethermistor sends fuel temperature data to theE.C.U, the E.C.U on receiving the data will adjustthe injector open time accordingly to producegood hot starting in high ambient temperatures.BYPASS AIR VALVE (STEPPER MOTOR)The bypass valve is screwed into a housing attachedto the rear of the plenum chamber, between theplenum chamber and bulkhead. The bypass valvehas two windings which enable the motor to beenergised in both directions thus opening orclosing the air valve as required by the E.C.U.The bypass valve will open and allow extra air intothe plenum chamber to maintain engine idle speedwhen the engine is under increased (Electrical andMechanical) loads.The bypass valve will control engine idle speedwhen the vehicle is stationary.LAMBDA SENSORS (0, SENSORS)The two Lambda sensors are located fonvard of thecatalysts mounted in the exhaust downpipes.The sensors monitor the oxygen content of theexhaust gases and provide feedback information ofthe air/fuel ratio to the E.C.U. Each sensor is heatedby an electrical element to improve its responsetime when the ignition is switched on.ContinuedREVISED: APR. 87 3


FUEL INJECTION SYSTEM1987 rGv;;FUEL PRESSURE REGULATORThe fuel pressure regulator is mounted in the fuelrail at the rear of the plenum chamber. Theregulator is a mechanical device controlled byplenum chamber vacuum, it ensures that fuel railpressure is maintained at a constant pressuredifference of 2.5 bar above that of the manifold.When pressure exceeds the regulator setting excessfuel is returned to the fuel tank.FUEL PUMPThe electric fuel pump is located in the fuel tank,and is a self priming ‘wet’ pump, the motor isimmersed in the fuel within the tank.AIR FLOW SENSORThe hot-wire air flow sensor is mounted on abracket attached to the left hand valance, rigidlyconnected to the air cleaner and by hose to theplenum chamber inlet neck.The air flow sensor consists of a cast alloy bodythrough which air flows. A proportion of this airflows through a bypass in which two wire elementsare situated: one is a sensing wire and the other isa compensating wire. Under the control of anelectronic module which is mounted on the air flowsensor body, a small current is passed through thesensing wire to produce a heating effect. Thecompensating wire is also connected to the modulebut is not heated, but reacts to the temperature ofthe air taken in, as engine intake air passes over thewires a cooling effect takes place.The electronic module monitors the reaction of thewires in proportion to the air stream and providesoutput signals in proportion to the air mass flowrate which are compatible with the requirements ofthe E.C.U.THROlTLE POTENTIOMETERThe throttle potentiometer is mounted on the sideof the plenum chamber inlet neck and is directlycoupled to the throttle valve shaft.The potentiometer is a resistive device suppliedwith a voltage from the E.C.U. Movement of thethrottle pedal causes the throttle valve to open,thus rotating the wiper arm within thepotentiometer which in turn varies the resistance inproportion to the valve position. The E.C.U.lengthens the injector open time when it detects achange in output voltage (rising) from thepotentiometer.In addition the E.C.U. will weaken the mixturewhen it detects the potentiometer output voltage isdecreasing under deceleration and will shorten thelength of time the injectors are open.When the throttle is fully open, the E.C.U. willdetect the corresponding throttle potentiometervoltage and will apply full load enrichment. This is afixed percentage and is independent oftemperature. Full load enrichment is also achievedby adjusting the length of the injector open time.When the throttle is closed, overrun fuel cut off oridle speed control may be facilitated dependant onother inputs to the E.C.U.ROAD SPEED TRANSDUCERThe road speed transducer is fitted between theupper and lower speedometer cables. It is mountedon a bracket located on the left hand chassis sidemember adjacent to the rear engine mounting. Thetransducer provides road speed data to the ECU.The ECU in turn detects vehicle movement fromthe road speed input and ensures that idle speedcontrol mode is disengaged. Should the speedtransducer fail in service the ECU idle speed controlwould become erratic.J:.....j4 REVISED: APR. 87


FOE; 1987FUEL INJECTION SYSTEM b ii\: ...,INERTIA SWITCHThe inertia switch is a mechanically operated switchlocated under the left hand front seat attached tothe seat base rear cross-member.The switch is normally closed and is in the ignitionfeed (fuse to fuel pump). In the event of a suddenimpact the switch opens, and disconnects theelectrical feed to the fuel pump. The switch is resetby pressing down the button.RELAYSThe two electronic fuel injection relays are locatedunder the front right hand seat mounted forward ofthe E.C.U. The main relay is energized via the E.C.Uwhen the ignition is switched on and suppliescurrent to the fuel injection system. The fuel pumprelay is energized by the E.C.U. which in turnoperates the fuel pump to pressurize the fuelsystem.E.F.I. WARNING SYMBOL (Instrument binnacle)An E.F.I. warning symbol incorporated into theinstrument binnacle will illuminate when the E.C.U.detects that it cannot maintain correct air/fuel ratiodue to a fault in one of the follolOring fuel injectionsystem components. ‘:. ,.*aAir flow sensor.Lambda sensor. -Water temperature thermistor. (sensor)Throttle potentiometer.., .’‘.’ :‘. ,‘,‘.‘. :::, ..i.’The symbol will illuminate on initial turn of theignition key as part of the bulb check feature, andwill go out after a few seconds.If the symbol illuminates when the engine is idlingor the vehicle is being driven it indicates a failure ofone of the four functions, the vehicle should bedriven with care, and the cause rectified, refer totest procedure for the particular functions. Shouldone of the functions fail, the vehicle can still bedriven due to a limp home feature incorporatedinto the fuel injection system..‘.,...:2: :_‘. ‘*. . .. .REVISED: JULY 88


1987 KANCltROVER”FUEL INJECTION SYSTEMCAUTION: The fuel system incorporates finemetering components that would be affected byany dirt in the system; therefore it is essentialthat working conditions are scrupulously clean.If it is necessary to disconnect any part of thefuel injection system, the system MUST bedepressurized. All openings left open after theremoval of any component from the fuel system,MUST be sealed off (0 prevent ingress of dirt.ENGINE SEllING PROCEDUREIf a major overhaul has been undertaken on the fuelinjection/engine system, the following check andadjustments must be carried out before attemptingto start the engine.A. Throttle potentiometer setting - see ‘Throttlepotentiometer’ setting procedure.B. Spark plug gaps - see ‘Section 05 Enginetuning data’.C. Throttle levers - see ‘Throttle lever settingprocedure’.D. Ignition timing - static - see ‘Section 86Electrical’.CAUTION: IF THE ENGINE IS MISFIRING, ITSHOULD BE IMMEDIATELY SHUT DOWN ANDTHE CAUSE RECTIFIED. FAILURE TO DO SO WILLRESULT IN IRREPARABLE DAMAGE TO THECATALYSTS.NOTE: If the previous checks and adjustmentsare satisfactory but the engine will not start theignition and fuel injection electrical circuitorymust be checked using the appropriaterecommended equipment.Recommended Equipment -Lucas ‘Electronic Ignition Analyser’Lucas Part Number - YWB 119.Lucas Diagnostic EquipmentLucas Part Number - 60600965 (complete kit)Individual part numbers for the above kit are asfollows:Hand held test unit - Model 2HHTLucas Part Number - 84772Interface unitLucas Part Number- Model 21U- 84773Serial link leadLucas Part Number - 54744753Memory cardLucas Part Number - 54744754Operating manualLucas Part NumberPlastic caseLucas Part Number. XXB825- 54744755NOTE: The Lucas diagnostic equipment can beconnected to the diagnostic plug located by theE.C.U.Use in conjunction with the Lucas OperatingInstruction Manuals.If the above equipment is unavailable the tests canbe carried out using a multi-meter, following the . .instructions given in the charts.CAUTION: Ensure the multi-meter is correctly setto volts or ohms, dependent upon which test isbeing undertaken.Carry out the following static checks beforeundertaking the continuity procedure:-::.I1.A.B.C.D.E.F.Fuse 18 - in main fuse panel - is intact.Inertia switch - not tripped.Fuel - ample fuel in fuel tank.Battery Condition - state of cha Ige.Air Leaks - no unmetered air entering enginesystem.Electrical Connections - dry, clean andsecure. .. . \6REVISED: jlJLY 88


o;;; 1987FUEL INJECTION SYSTEM: ”CONTINUITY TEST PROCEDURE..’ .IThe continuity procedure and instructions on thefollowing pages must be followed precisely toprevent damage occurring to any of the fuel systemcomponents.,’...‘.,.’To enable the tests to be carried out when the 40way multi-plug is connected to the E.C.U., it isnecessary to remove the two screws securing theshroud to the plug to enable the multi-meterprobes to be inserted into the back of theappropriate pin.CAUTION: Tests that require the plug to beremoved from the E.C.U., must also have themeter probes inserted into the back of the plug.If the probes are inserted into the plug sockets,damage will occur to the sockets resulting inpoor connections when the plug is reconnected.TESTING1. Remove the E.C.U., and harness plug frombeneath the front right hand seat, access isgained through the rear opening of the seatbase.2. Remove the plug shroud and maneuver italong the harness until there is enoughclearance enabling meter probes to beinserted into the back of the plug.3. There are 4 pin numbers, 1, 13, 28, 40moulded onto the rear of the plug for pinposition identification as shown in theillustration below, (for clarity the electricalleads have been omitted).Pins 1 to 13 top row.Pins 14 to 27 centre row (Pin 14 is below pin 13but is not identified on the rear of the plug).Pins 28 to 40 bottom row.PIN NOS.CABLE COLOUR1. Red/green2. Brown/orange3. Yellow4. Black5. Brown/purple6. Yellow7. Green/blue8. Not used9. White/light green10. Black/Yellow11. Yellow/white12. Blue/redI 3. Yellow/blue14. Black15. Brown16. Blue/purple17. Not usedI 8. White/pink19. Whitelgrey20. Red21. Yellow/blue22. Blue/red23. Blue24. Blue25. Red/black26. Green/white27. Black/grey28. Blue/grey29. Orange30. Not used31. Not used32. Greylwhite33. Not used34. Black/orange35. Blue/green36. Not used37. White/yellow38. Not used39. White/black40. BlackThe last colour denotes the wire tracer colour.Continued:’ 3.-. RR2016E 40 28; . .‘.REVISED: APR. 88


FUEL INJECTION SYSTEM1987 ;;“d’;‘;;iTESTS - Using a Muhi-MeterThe following continuity tests are intended as a guide to identifying where a fault may be within a circuit;reference should be made to the fuel injection circuit diagram for full circuit information.KEYTO SYMBOLSiNlTlON SWITCbELECTRONIC CONTROL UNITAND MULTIPLUGTEMPORARYCONNECTIONOHMMETERCONNECTIONSVOLTMETERCONNECTIONSMAIN RELAYPUMP RELAYFUEL PUMPROAD SPEEDINPUT (SPEEDTRANSDUCER)GEARINPUT SWITCHINHIBITORSWITCHINJECTORIGNITION COILFUELTEMPERATURESENSORCOOLANTTEMPERATURESENSORAIR BYPASSVALVETHROTTLE ’‘OTENTIOMETER 1HOT WIRE AIRFLOW SENSORRR1782E8REVISED: APR. 88


”R”;;; 1987FUEL INJECTION SYSTEM b-6 1NOTE: All tests are carried out from the electronic control unit (ECU) harness multi-plug unless statedotherwise in the test procedure.rEST PROCEDURE1. Check battery supply to ECURESULTS . Check cables and units shown in boldVoltmeter reading of battery volts -(mimimum battery voltage 10 volts)Proceed to Test 2Voltmeter reading of zero voltsCheck:-1RRl816EIGNlTlON OFF..1rEST PROCEDURE2. Check ignition supply to ECURESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -(minimum battery voltage 10 volts)Proceed to Test 3Incorrect reading check:-:,:.:.ARR1817EYContinued:REVISED: APR. 88g .::.,


l-lRANGE19 FUEL INJECTION SYSTEM lg8’ ROVER1rEST PROCEDURE. I. Check operation ofMain relayRESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Proceed to Test 5Voltmeter reading of zero volts -Proceed to Test 4IGNITION ONRR1818E5‘EST PROCEDURE 1 RESULTS - Check cables and units shown in bold4I.Fault DiagnosisMain relay circuitsA. Voltmeter reading of battery volts -Check:-If OK Suspect ECU6. Voltmeter reading of zero voltsCheck:---..~cl I-lGNsnoNoPFRiR1810E-4‘- ‘\1 0REVISED: APR. 88


k”d;‘;r; 1987‘EST PROCEDUREFUEL INJECTION SYSTEM 119 1RESULTS - Check cables and units shown in boldi. Check operation Listen for audible ‘click’ from pumpof pump relayrelay.If 0.K - Proceed to Test 7No audible ‘click’ from pump relayCheck:-If OK proceed to Test 6.IGNtTION ONRR182OE[EST PROCEDUREi. Fault diagnosisPump relay circuitsRESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Suspect ECUVoltmeter reading of zero voltsCheck:-IGNITION ON?R1821E1 IYContinuedREVISED: APR. 88


EST PROCEDURERESULTS - Check cables and units shown in bold7. Check operation of Fuel pump Voltmeter reading of battery volts -Pump operating - Proceed to Test 8NOTE: It is not possible lo place themulti-meter probes directly onto thepump terminals. A link lead attachedto the pump is accessible behind thereal left hand wheel located betweenthe chassis and stowage area floorpanel.(A)Voltmeter reading of batteryvolts -Pump not operatingCheck:‘-KEY:1. Inertia switch2. Fuse 18(6) Voltmeter reading of zero voltsCheck:-REVISED: APR. 88


K’^d;\ir; 1987~~‘EST PROCEDUREI. Check engine speed signalCable and resistorFUEL INJECTION SYSTEM 119 1RESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Proceed to Test 9Voltmeter reading of zero voltsCheck:-W1823ETEST PROCEDURE9. Check injectors,Injector circuit(Pin 13 left bank injectors 1,3,5,7).RESULTS - Check cables and units shown in boldOhm-meter reading of 4-5 Ohms -Proceed to Test 10Ohm-meter reading of 5-6 Ohms -Suspect 1 injectorOhm-meter reading of 8-9 Ohms -Suspect 2 injectorsOhm-meter reading of 16-17 Ohms -Suspect 3 injectorsCheck for open circuit injector(s)or wiring faults.Ohm-meter reading of InfinityCheck:cl I-IGNITION OFFlR1824 E..Continued.:.1.‘:; .( : . .,‘. .::i.. .~REVISED: APR. 88 13..:“,‘.;.


FUEL INJECTION SYSTEM. \. ..’-:;,.i :.. ‘. ..’. .::’?,‘EST PROCEDURE0. Check injectorsInjeclor circuitpin II rightbanknjectors 2,4,6,6)RESULTS - Check cables and units shown in boldOhm-meter reading of 4-5 Ohms -Proceed to Test 11.Ohm-meter reading of 5-6 Ohms -Suspect 1 injectorOhm-meter reading of 8-9 Ohms -Suspect 2 injectorsOhm-meter reading of 16-17 Ohms -Suspect 3 injectorsCheck for open circuit injector(s) or wiring faults.Ohm-meter reading of InfinityCheck:10. . i.0 L-IGNITION OFFRR1825ETEST PROCEDURE11. Check fuel temperaturethermistor (sensor)11RESULTS - Check cables and units shown in boldCorrect reading-temperature toresistance- Proceed to Test 12(Refer to Temperature ConversionCharts in Test 12Incorrect Ohm-meter readingCheckI-clIGNITION OFFRR1826E1 4 REVISED: APR. 88


;;^d;;t; 1987FUEL INJECTION SYSTEM 119 1‘EST PROCEDURE2. Check coolant temperaturethermistor (sensor)RESULTS - Check cables and units shown in boldCorrect reading-Temperature toresistance- Proceed to Test 13(Refer to Temperature ConversionChart below.Fuel and Coolant Ohm-meter ReadingTemperatureShould be“C “F Ohms-100 140 9100 - 930000 32" 5700 - 5900200 680 2400 - 2600400 1040 1100 - 130060" 1400 500 - 70080° 176O 300 - 4001000 2120 150 - 200Incorrect Ohm-meter readingCheck:-0 I- - -IGNtllON OFFRR1827EContinuedREVISED: APR. 88 15


-tI19 FUEL INJECTION SYSTEM-.- - -.wIMT PROCEDURERESULTS - Check cables and units shown in bold13. Check air bypass valve - Part I Ohm-meter reading of 48-58 Ohms -Proceed to Test 1413Incorrect readingCheck:-IGNlTtON OFFRR1828EITEST PROCEDURERESULTS - Check cables and units shown in bold14. Check air bypass valve - Part 2IOhm-meter reading of 48-58 Ohms -Proceed to Test 15Incorrect readingCheck:-I0I3 -IGNITION OFF‘.Y. .,‘.*::, ‘.1 6REVISED: APR. 88


. 1KHNCIt 1987ROVER FUEL INJECTION SYSTEM 119 .[EST PROCEDURE15. Check throttle potentiometer - Part 1RESULTS - Check cables and units shown in boldOhm-meter reading of 5000 Ohms -Proceed to Test 16Incorrect reading of InfinityCheck:-15u3NIlloN OfTRA1830ErEST PROCEDURE16. Check throttle potentiometer - Part 2RESULTS - Check cables and units shown in boldCorrect voltmeter readings-Proceed to Test 17.ThrottleclosedThrottleopen0.29 ) ( 4.6 Volts) smooth () __....__...___________ (0.36 ) swing ( 5.0 VoltsIncorrect voltmeter readingsCheck:-- I -C I -’ I ’IGNITION ONRRl831E 4ContinuedREVISED: JUNE 87 17:.


RANGE19 FUEL INJECTION SYSTEM “*’ ROVER‘EST PROCEDURE17. Check ou~pul ofAirflow sensorRESULTS . Check cables and units shown in boldVoltmeter reading of 0.3-0.6 volts-Proceed to Test 18Incorrect voltmeter readingCheck:-- IGNITION ONwPRECAUTION:Depressurize the fuel system when fitting the fuel pressure gauge or disconnecting/replacing fuel systemcomponents.CAUTION: Thoroughly clean the immediate area around the fuel filter and hose connections beforedisconnecting the fuel feed line from the filter. Failure to do so could cause foreign matter to bepresent in the fuel system which would be detrimental to the fuel system components.WARNING: The spillage of fuel from the fuel filter is unavoidable when disconnecting the fuel feedline, ensure that all necessary precautions are taken to prevent fire and explosion due to fuel vapourand fuel seepage. .DEPRESSURIZING PROCEDURE .a) Ignition off, pull pump relay off its terminal block.b) Crank engine for a few seconds - engine may fire and run until fuel pressure is reduced.cl Switch off the ignition.d) Connect fuel pressure gauge in the fuel supply line between the fuel rail and the fuel filter, adjacent tothe filter (see Test 18).e) Reconnect the pump relay.1.,i18 REVISED: JUNE 87,.,:.:


FUEL INIECTION SYSTEM 119 1NOTE: Insert the pressuregauge in the fuel feed lineimmediately after the fuelline filter. The filter islocated beneath the righthand rear wheel arch attachedto the chassis(34.0-37.0 p.s.i.)(6) Pressure drop-max 0.7 kgflcm’(IO p.s.9 in one minute,’ ‘.’IGMTION OFF1R1833E::;Continued‘..(. ‘.19


FUEL INJECTION SYSTEMRANGElg8’ ROVEREST PROCEDURERESULTS - Check cables and units shown in bold9. Check for leaking injector WARNING: Ensure that allnecessary precautions are takenNOTE: Before removing anyof the injectors, remove andexamine the spark plugs.check for consistenlcolouration of plugs.A leaking injector willresult in the appropriatespark plug being ‘sooted up’.IO prevent fire and explosion.Replace any injector which leaksmore than 2 drops of fuel per minute.Remove all injectors frommanifold but do notdisconnect from fuel railtR1834E,’


I---;rot;; 1987rEST PROCEDURE!O.Check for injector operationLeft bank injectors 1,3,5,7FUEL INJECTION SYSTEMRESULTS - Check cables and units shown in boldWARNING: Ensure that allnecessary precautions are takenIO prevent fire and explosion.Repeat test for other injectorsReplace any injector which does notoperate.NOTE: Fuel flow is 167cc minimumper minute per injeclor20 \rEST PROCEDURE11. Right bank injectors 2,4,6,6RESULTS - Check cables and units shown in boldWARNING: Ensure that allnecessary precautions are takenIO prevent fire and explosionRepeat test for other injectorsReplace any injector which does notoperateNOTE: Fuel flow is 167cc minimum perminute per injectorIGNITION ONContinued


FUEL INJECTION SYSTEMRANGElg8’ ROVER‘EST PROCEDURE!2. Check gear switch inputRESULTS - Check cables and units shown in boldVoltmeter reading of zero volts-Neutral and parkVoltmeter reading of 4.5-5.0 Volts-R.D.3.2.1 - Proceed to Test 23Incorrect readingCheck::.RR1837E1otw10r-d ON‘.‘.:.‘: .,:.‘. .’ ,‘:.. . .‘


o7;; 1987FUEL INJECTION SYSTEM Ii9 1‘EST PROCEDURERESULTS - Check cables and units shown in bold.‘,,::. :.‘_’:3. Check road speed inputNOTE: Raise and rotate the left handrear road wheel slowlyVoltmeter reading of 0 to 12V fluctuating 6 times perrevolution - Proceed to Test 24Incorrect readingCheck:;...i; ]‘..,‘. .IGNITCON ONRR1838E‘. :;rEST PROCEDURERESULTS . Check cables and unils shown in bold:‘. *24. Check Lambda sensor heater coilsNOTE: Remove pump relay from its conneclorOhm-meter reading of 2.65-3.35 OhmsIncorrect readingCheck:NOTE: A reading of 5.3 lo 6.7 Ohms indicates a faultyLambda sensor.,‘.24,,,:‘:IGNITION OFFRR1840EAfter completing the tests with either the ‘Diagnostic’ equipment or multi-meter, re-test the vehicle to ensurethe faults have been rectified. If faults still persist, recheck using the Lucas diagnostic equipment.2 3


FUEL INJECrlON SYSTEMENGINE TUNING PROCEDUREBefore carrying out ‘Engine Tuning’ on fuel injectionvehicles, it is important that all other engine relatedsetting procedures are undertaken first; air flowsensor to air cleaner correctly fitted, ignition andthrottle potentiometer correcty set; all hosescorrectly fitted and secured.These checks should be carried out with the enginecoolant temperature beween 80” to 95°C (176” to203°F).CHECK AND ADJUST IGNITION TIMING1. Check that ignition timing is at 6” 2 1” BTDC.2. Timing to be checked when engine speed isless than 800 rev/min using a stroboscopiclamp.3. If adjustment is necessary, loosen thedistributor clamp nut and rotate clockwise toretard or ‘counter -clockwise to advance. Whenthe required setting has been attained, tightenthe clamp nut and recheck the setting.NOTE: Timing to be checked with vacuumhose connected.IDLE SPEED is preset at the factory and shouldnot normally require adjustment.CAUTION:A. If engine fails to start within a maximum timeof 12 seconds the cause must be rectified.Following rectification the engine must be runat 1500 rpm (no load) for 3 minutes to clearany accumulation of fuel in the catalysts.B. If the engine is misfiring, it should beimmediately shut down and the causerectified.Failure to comply with A or B will result inirreparable damage to the catalysts.24


.:yo;;; 1987AIR CLEANERAIR FLOW SENSORFUEL INJECTION SYSTEM 119 1.tRemove and RefitRemove and refit:j,,:.:“.’:::..., .,Removing1.2.3.4.5.7.8.9.Release the two clamps securing the aircleaner to the airflow sensor.Release the two nuts and bolts securing the aircleaner to the left hand valance mountingbracket.Detach the airflow sensor from the air cleaner,and lay carefully to one side.Detach the air cleaner from the centremounting bracket and withdraw from theengine compartment.Remove the large ‘0’ ring from the outlettube of the air cleaner, inspect for condition,fit a new ‘0’ ring if in poor condition.Unclip the three catches securing the inlettube to the air cleaner canister and removethe inlet tube.Remove the nut and end plate securing the aircleaner element in position.Withdraw the air cleaner element and discard.Inspect the dump valve for condition and thatit is clear of obstructions.RemovingNOTE: The air flow sensor is not aserviceable item. In the event of failure ordamage the complete unit is to be replaced.Disconnect the battery negative terminal.Release the large hose clamp at the rear of theair flow meter and disconnect the hose fromthe sensor.Disconnect the multi-plug.Release the two clips securing the air flowsensor to the air cleaner case detach thesensor from the case and withdraw it from theengine compartment.. .,;;: ‘.,“.,..‘, ‘.’,::;’ ‘... ‘...; . .RFiI854ERefitting5. Reverse the removal procedure ensuring thatthe multi-plug is firmly reconnected to the airflow sensor and that the hose clamp at therear of the sensor is securely tightened, toprevent un-metered air entering the engine.‘,.,:’.’,’ . .::.,.,..‘.‘.,Refitting10. Fit a new element and secure in position.11. Refit the inlet tube to the air cleaner canister.12. Refit the air cleaner to the mounting bracketand tighten the two nuts and bolts.13. Clip the air flow sensor to the air cleaner.‘.;.REVISED: SEPT. 88 25.:...


FUEL INJECTION SYSTEMTHROlTLE POTENTIOMETER1987 &INGEROVERSetting the Potentiometer using a multi meter.‘.._,. ”:,.Remove, refit and resetRemove1. Disconnect the battery negative terminal.2. Disconnect the electrical three-pin plug.3. Remove the two screws securing the switch tothe plenum chamber and carefully pull theswitch off the throttle valve shaft.ENSURE THE MULTI METER USED TO CARRY OUTTHIS CHECK IS SET TO VOLTS. A MULTI METERSETTING OTHER THAN VOLTS WILL RESULT INDAMAGE TO THE POTENTIOMETER.8.9.10.11.12.13.Loosen the potentiometer securing screws.Reconnect the potentiometer three-pin plugand reconnect the battery. Switch on theignition.Connect the multi meter between the red andgreen leads at the potentiometer electricalplug.Rotate the potentiometer clockwise orcounter-clockwise, until the multi meter reads3252 35 mV.Tighten the potentiometer securing screws.Re-check the multi-meter reading. Check alsofor a ‘smooth swing’ of the meter needlebetween minimum and maximum throttleopening between the voltage reading of 4.6 -5.0 volts4. Remove the old gasket.Refit5. Fit a new gasket between the throttle switchand plenum chamber.6. Align the switch and shaft fiats; slide theswitch on to the throttle shaft and secure theswitch to the plenum chamber.7. The throttle potentiometer must be resetusing the following procedure.NOTE: After setting the potentiometer, lockand tamperproof each screw head bycoating them with yellow paint.CAUTION: The throttle mechanism must not beoperated while the potentiometer is looselyfitted, otherwise damage may be caused to thepotentiometer wiper track.26 REVISED: SEPT. 88


R”d;‘;r; 1987FUEL INJECTION SYSTEM 119 1:.,’ :..’ .:,:: ;...BY-PASS AIR VALVE(STEPPER MOTOR)Remove and refitRemoving1.2.3.4.Disconnect the battery negative terminal.Remove the multi-plug from the unit.Unscrew the valve from its location at the rearof the plenum chamber.Remove the captive washer.SPEED TRANSDUCERRemove and refitRemoving1.2.3.4.5.6Place the vehicle on a hydraulic hoist andapply the parking brake.Disconnect the battery negative terminal.Raise the hoist and disconnect the speedtransducer electrical plug.Disconnect the speedometer cable from thetransducer to the binnacle at the transducer.Disconnect the speedometer cable from thetransducer to the speedometer housing at thetransducer.Remove the single bolt securingtransducer to its mounting bracketwithdraw the unit from the vehicle.t h eand,’ ,~:Refitting5. Fit a NEW sealing washer..’‘. 1‘, :. 8:,, ‘,‘,, :,.. NOTE: If:::: .’refittedthe same by-pass valve is beingclean any previous sealingcompounds from the threads. Apply Loctite241 to threads of the valve beforereassembly.Refitting7. Reverse the removal instructions..: ‘, :.:,: .‘: :., ,’ ‘, ,‘.,I.‘,.;,,;,. ; : :6. Tighten the valve to the specified torque (seeTorque values-section 06).7. Reverse the remaining removal instructions.J:.::,, ..,‘. :,.:27


FUEL INJECTION SYSTEM:ELECTRONIC FUEL INJECTION RELAYSincorporated into the fuel injection electrical circuitsare two relays. The relays are located beneath thefront right-hand seat, adjacent to the E.C.U.ELECTRONIC CONTROL UNIT-ECUNOTE: The ECU is not itself a serviceableitem, in the event of a unit failure, the ECUmust be replaced.‘,,,.’I1.Fuel pump relay (mounted on a blueterminal block).Main relay (mounted on a black terminalblock).Diagnostic plug.Remove and refitRemoving1.2.3.4.5.6.7.Disconnect the battery negative terminal.The ECU is located under the front right handseat and is accessible through the rearopening of the seat base when the seat is inits most forward position.Release the E.C.U plug retaining clip.Pull the rear of the multi-plug out of the ECU.Maneuver the tront of the plug fin thedirection of the bold arrow) to release the 1hooked rear end of the plug from theretaining peg.Release the screws securing the ECU to themounting bracket.Withdraw the ECU from the spring clip andremove it from the vehicle.,:’ .i .rRRl867ERemove and refitRemoving1. Disconnect the battery negative terminal.2. Pull the relay(s) from the multi-plug(s).Refitting3. Reverse the removal procedure.Refitting8. Refit the E.C.U. securely in’the spring clip andtighten the two screws.9. Re-connect the E.C.U. harness plug, ensurethe plug is firmly pushed into its location andthat the retaining clip secures the plug inposition.4.’8.:‘,:,: ..,.. ‘.28


FUEL INJECTION SYSTEMINERTIA SWITCHThe inertia switch is located under the left handfront seat attached to the inner face of the rearfront seat base. Access to the switch is gainedthrough the opening at the rear of the seat base.Remove and refitRemoving1. Ensure the seat is in its fully forward position.2. Disconnect the battery negative terminal.3. Remove the two screws securing the switch tothe cross member.4. Withdraw the switch and disconnect theelectrical multi-plug.5. Remove the switch from the vehicle.FUEL TEMPERATURE THERMISTOR (SENSOR)Remove and refitRemovingNOTE: No fuel leakage will occur when thethermistor is removed from the fuel railtherefore it is not necessary to depressurize thefuel system before removal.1. Disconnect the battery negative terminal.2. Remove the electrical multi - plug from thethermistor.3. Release the thermistor from the fuel feed rail.Refitting6. Reverse the removal procedure ensuring thatthe multi-plug clips firmly into position, andthat the plunger is reset (plunger is in itslowest position).Refitting4. Reverse the removal procedure, ensuring thatthe thermistor is tightened securely in the fuelrail.REVISED: APR. 88 29: .:


-19 FUEL INJECTION SYSTEMKANW1987-88 R(-j”ERCOOLANT TEMPERATURE THERMISTOR (SENSOR)Remove and refitRemoving1.2.3.4.5.Remove the multi-plug from the thermistor.Release the radiator bottom hose and partiallydrain the cooling system.Refit the hose and tighten the clamp securely.Remove the thermistor from the left handfront branch of the intake manifold.Remove the copper washer.RESETTING THROTTLE LEVERSNOTE: The setting procedure outlined isapplicable at minimum throttle conditiononly.Ensure that the throttle valve is retained at its90” vertical setting by holding down the stoplever and throttle/kick down lever denoted bythe bold arrow while adjusting the throttleoperating levers.Release the throttle operating lever securingscrew and adjust the lever until contact ismade with the top end of the slot in thethrottle lever mounting bracket; retaining thelever in this position retighten the screw.Lightly grease all throttle lever bearing surfacesand torsion spring with Admax 13 grease or asuitable equivalent.Refitting6.7.8.9.Fit a NEW copper washer to the thermistor.Fit the thermistor to the intake manifold andtighten securely.Refill the cooling system.Run the engine, check for water leaks aroundthe coolant temperature thermistor.NOTE: Check the clearance between thecruise control actuator link and throttlelever (see Cruise Control ActuatorSetting-Section 19, Page 47).LATER MODELS:- have a redesigned stop lever thatseats on a factory-set adjustment screw which islocated in the plenum chamber casting. The screwshould not normally require adjustment. If newthrottle bracketry and linkages are fitted it isadvisable to check that the throttle valve is verticalbefore adjusting the screw..__30REVISED: APR. 88 :,.._..


FUEL INJECTION SYSTEM1THROl-FLE CABLERemove and refitRemoving1.2.3.Remove the cotter pin and clevis pin securingthe cable to the lever.Carefully pry the throttle cable adjustment nutout of the linkage mounting bracket.Withdraw the cable from the mountingbracket.10. Connect the cable to the throttle linkage, fit anew cotter pin and secure in position.11. Clip the outer cable adjustment nut into themounting bracket.12. Adjust the outer cable to give 1.57 mm (0.062in) free play in the throttle cable and checkthe throttle operation.THROlTLE PEDALRemove and refitRemoveRRl064Ei,io 2,i2Release the outer cable from the retainingclips within the engine compartment.Remove the lower dash pane! from beneaththe steering column.Disconnect the cable from the throttle pedaland release the cable locknut.Feed the cable through the bulkhead grommetand into the engine compartment.1. Release the six screws securing the lower dashpanel, lower the panel and disconnect the twoelectrical leads to the rheostat switch, detachthe bulb check unit from the spring clip andremove the dash panel from the vehicle.Remove the cotter pin and clevis pin securingthe throttle cable to the throttle pedal.Release the tension from the pedal returnspring.Remove the circlip from the pedal pivot pin.Withdraw the pivot pin.NOTE: It may be necessary to remove thesteering column fixings enabling thecolumn to be lowered to gain access to thepedal pivot pin circlip.6. Withdraw the throttle pedal.FIT NEW THROlTlE CABLERefitting7. Lightly grease the pivot4pin and clevis pinbefore re-assembly.8. Fit a NEW cotter pin to the clevis pin.9. Reverse the remaining removal instructions.8. Feed the new cable from the enginecompartment through the bulkhead grommet.9. Connect the cable to the throttle pedal.31


FUEL INJECTION SYSTEM1987-88 PO;;;PLENUM CHAMBERRemove and refitRemoving12. Release the two throttle return springs.13. Remove the two bolts (with spring washers)securing the throttle cable and kick-downcable anchor bracket to the throttle leversupport bracket, lay the assembly to one side..’ 1::1.2.3.4.8.Disconnect the battery negative terminal.Release the radiator bottom hose and partiallydrain the cooling system, reconnect the hoseto the radiator.Release the two large hose clamps from theneck of the plenum chamber and outlet boreof the airflow sensor and remove the hosefrom its location.Release the clamps and remove the twocoolant hoses from the bottom of the plenumchamber inlet neck. Identify each hose to aidre-assembly.Remove the vacuum supply hose from thecruise control actuator.Disconnect the actuating link at the cruisecontrol actuator.Remove the distributor vacuum hose, positivecrankcase ventilation breather filter hose andservo hose.Disconnect the throttle potentiometermulti-plug.14.15.Remove the six socket head bolts (with plainwashers) securing the plenum chamber to theram housing.Maneuver the plenum chamber and remove itfrom the ram housing.,NOTE: To prevent ingress of dirt into theram tubes, place a protective cover over theram tube openings.i9.10.11.Disconnect the multi-plug from the air by-passvalve.Disconnect the small vacuum hose at the rearof the plenum chamber, located below the airby-pass valve.Remove the hose from the air by-pass valve toplenum chamber to enable the small returnspring located below the throttle levers to beunhooked.: ::.3 2‘,, .:,:::,: ‘,‘.


;;“d;‘;;i 1987-91FUEL INJECTION SYSTEMRefitting16. Ensure that all mating faces are free from anyprevious sealing compounds.17. Coat the mating faces of the plenum chamberand ram housing with ‘Hylomar’ sealant.18. Refit the plenum chamber and tighten the sixbolts to the specified torque (see torquevalues-section 06).19. When refitting the small return spring, item 11in the removal procedure, it must be notedthat the ‘hooked’ open end of the springMUST face the plenum chamber as shown inillustration RR2292E below.RAM HOUSINGRemove and refitRemoving1. Disconnect the battery negative terminal.2. Remove the plenum chamber (see PlenumChamber remove and refit).3. Release the hoses from around the outeredges of the ram housing.4. Remove the six through bolts (with plainwashers) securing the ram housing to theintake manifold.20. Reverse the remaining removal instructions.NOTE: Ensure that all hoses are connectedsecurely to prevent un-metered air enteringthe engine.5. Lift the ram housing off the intake manifoldand remove it from the engine compartment.6. Place a protective cover over the top of theintake manifold inlet bores to prevent ingressof dirt.Refitting7. Ensure that all mating faces are clean and freefrom dirt and any previous sealingcompounds.8. Apply ‘Hylomar’ sealant to the intake manifoldface before refitting the ram housing.9. Fit the ram housing and retighten the bolts,working from the two centre bolts, diagonal11towards the outer four bolts.10. Tighten to the correct torque (See section06-Torque values).REVISED: SEPT. SO 33;: _:


FUEL INJECTION SYSTEM1987-91 PO;;;DEPRESSURIZING THE FUEL SYSTEMWARNING: Under normal operating conditionsthe fuel injection system is pressurized by a highpressure fuel pump, operating at up to 2.3 to 2.5bar (34 to 37 p.s.i.1. When the engine isstationary this pressure is maintained within thesystem. To prevent pressurized fuel escaping andto avoid personal injury it is necessary todepressurize the fuel injection system beforeany service operations are carried out.NOTE: If the vehicle has not been run there willstill be a small amount of residual pressure inthe fuel line. The depressurizing procedure muststill be carried out before disconnecting thecomponent within the fuel system.WARNING: The spilling of fuel is unavoidableduring this operation. Ensure that all necessaryprecautions are taken to prevent fire andexplosion.FUEL PRESSURE REGULATORRemove and refitRemoving1.2.3.4.5.6.Depressurize the fuel system.Disconnect the negative battery terminal.Release the hose clamp securing the fuelreturn hose to the regulator and remove thehose.Pull the vacuum hose from the rear of theregulator.Remove the two nuts and bolts securing theregulator to the fuel rail, carefully ease theregulator fuel inlet pipe out of the fuel rail.Withdraw the regulator from the enginecompartment.1.2.3.4.5.The fuel pump relay is located under the frontright hand seat.Pull the fuel pump relay off its multi-plug (seeElectronic Fuel Injection Relays-Section 19,Page 28).Start and run the engine.When sufficient fuel has been used up causingthe fuel line pressure to drop, the injectorswill become inoperative, resulting in enginestall. Switch the ignition off.Disconnect the battery negative terminal.6.NOTE: Fuel at low pressure will remain inthe system. To remove this low pressurefuel, place an absorbent cloth around thefuel feed hose at the fuel rail and releasethe fuel feed hose at the appropriate end.Disconnect either:a) The nut and ferrule at the fuel railORb) The hose at the inlet end of the fuel filter. RefittingNOTE: If the original regulatorrefitted, fit a NEW ‘0’ ring to thepipe.is beingfuel inletRefitting 7.7. Refit the fuel feed hose.8. Refit the fuel pump relay, reconnect thebattery.9. Crank the engine (engine will fire withinapproximately 6 to 8 seconds).8.9.Lightly coat the ‘0’ ring with silicon grease300 before fitting the regulator to the fuel rail.Reverse the removal procedure.Reconnect the batter), and pressurize the fuelsystem and check that there are xo fuel leaksaround the regulator connections.34 REVISED: SEPT. 90


;;^d;‘;; 1987-88FUEL INJECTION SYSTEM,’,’ .’FUEL RAIL-INJECTORS R/H AND UHRemove and refit11. If necessary, remove the two nuts and boltssecuring the regulator to the fuel rail, andcarefully pull the regulator away from the rail.Removing1.2.3.4.Depressurize the fuel system.Disconnect the negative battery terminal.Remove the plenum chamber. (See PlenumChamber, remove and refit).Remove the ram housing. (See Ram Housingremove and refit).NOTE: Place a cloth over the ram tubeopenings to prevent ingress of dirt into theengine.5.. .‘.‘...‘,. . .,‘,.,., ., ,‘..._ .’ .., 6.‘..: ‘:7.8.Release the hose clamp and remove the fuelreturn hose from the pressure regulator.Disconnect the multi-plug from the fueltemperature thermistor (sensor).Disconnect the multi-plugs from the eightinjectors.Remove the five bolts securing the fuel railsupport and heater pipe brackets to the intakemanifold. Lay the heater pipes to one side.Refitting12. Fit NEW ‘0’ rings, protective cap andsupporting disc to the injectors, lightly coatthe ‘0’ rings with silicon grease 300 and insertthe injectors into the fuel rail, multi-plugconnections facing outwards.13. Refit the retaining clips.CAUTION: Care must be taken when refitting thefuel rail and injectors to the intake manifold toprevent damage occurring to the ‘0’ rings.14.15.16.17.Fit a NEW ‘0’ ring to the pressure regulatorlightly coat the ‘0’ ring with silicon grease 300and secure the regulator to the fuel rail.Fit the fuel rail and heater pipe assemblies tothe intake manifold, secure the rail and pipesin position with the five bolts.Reverse the remaining removal instructions.Pressurize the fuel system and check for fuelleaks around the injectors and pressureregulator.9. Remove the fuel rail, complete with injectors,from the intake manifold.10. Remove the retaining clips securing theinjectors to the fuel rail, ease the injectorsfrom the rail.--- .,. . . . . .‘...


FUEL INJECTION SYSTEM1987-88 yo$;;INTAKE MANIFOLDRemove and refitRemovingDepressurize the fuel system.Disconnect the battery negative terminal.Release the hose clamp and remove theradiator bottom hose to enable the coolingsystem to be partially drained, so that coolantlevel is below the thermostat housing, refit thehose and secure in position with the hoseclamp.Remove the plenum chamber (see PlenumChamber, remove and refit).Remove the ram housing (see ram housingremove and refit).CAUTION: Place a protective cover over theintake manifold openings to prevent ingress ofdirt.6.7.Disconnect the electrical multi-plugs to thefuel temperature thermistor (sensor), coolanttemperature thermistor (sensor) and injectors.Remove the two nuts and bolts securing thepressure regulator to the fuel rail, ease theregulator out of the rail, seal the end of thefuel rail with suitable plastic plugs to preventingress of dirt.NOTE: The intake manifold can be removedfrom the cylinder block without removingthe fuel rail and injectors.13. Lay the heater pipe assembly to one side.14. Release the twelve bolts securing the intakemanifold to the cylinder heads.15. Lift the manifold off the cylinder heads andremove from the engine compartment.16. Remove the two gasket clamps from the topof the cylinder block.17. Lift off the gasket and remove the gasketseals.18. Remove previous sealing compound fromaround the water passage openings of thecylinder heads.Refitting19. Locate the NEW seals in position with theirends engaged in the notches formed betweenthe cylinder heads and block.8.9.10.11.12.Disconnect the electrical leads from theair-conditioning engine coolant sensor locatedon the thermostat elbow.Disconnect the electrical leads to the coolanttemperature transmitter (sensor) located at thefront of the intake manifold.Remove the injector harnesses from behindthe fuel rail and lay to one side.Release the hose clamps securing the twoheater hoses to the rigid heater pipes at thefront of the right hand rocker cover.Remove the two bolts securing the rigidheater pipes to the intake manifold and easethe pipes out of the hoses., ‘.20. Lightly apply ‘Hylomar’ sealant around theoutside of the water passage openings on thecylinder heads, manifold gasket and intakemanifold.?‘.,,.‘I,:36iz,‘..


FOE; 1987-91FUEL INJECTION SYSTEMFUEL FILTER. .‘. :.Remove and refit.,:: :: ”20121.22.23.24.25.26.27.28.29.Fit the manifold gasket with the word ‘FRONT’to the front and the open bolt hole to thefront right hand side.Fit the gasket clamps but DO NOT fullytighten the bolts at this stage.Locate the intake manifold onto the cylinderheads, clean the threads of the manifoldsecuring bolts.Fit all manifold bolts and tighten them a littleat a time, evenly, alternate sides working fromthe centre outwards.Tighten to correct torque (see section 06Torque values).Tighten the gasket clamps to the correcttorque (see section 06 Torque values).Reverse remaining removal instructions.Replenish the cooling system.Start the engine, check for water and fuelleaks.RefittingWARNING: The spilling of fuel is unavoidableduring this operation. Ensure that all necessaryprecautions are taken to prevent fire andexplosion.1.2.3.4.5.Depressurize the fuel system.The fuel filter is located on the right handchassis side member fotward of the fuel tankfiller neck. Access to the filter is gainedthrough the right hand rear wheel arch.Thoroughly clean the immediate area aroundthe hose connections to prevent ingress offoreign matter into the fuel system.Loosen the two hose clamps nearest the filterto enable the hoses to be removed from thefilter canister. Plug the end of the hoses toprevent ingress of dirt.Release the securing bolt and bracket andremove the filter from the chassis sidemember.Refitting6. Fit a new filter observing the direction of flowarrows stamped on the canister.7. Start the engine and inspect for fuel leaksaround the hose connections.REVISED: SEPT. 90 37


‘. 8.‘_’.:‘. .’‘,FUEL TANKFUEL INJECTION SYSTEMRemove and refitRemovingWARNING: Ensure that the Fuel HandlingPrecautions given in Section 01 - Introductionregarding fuel handling are strictly adhered towhen carrying out the following instructions.KANGIZ1987-91 ROVERIO. Release the two large hose clamps, securingthe inter-connecting hose to tank and fillertube, maneuver the hose up the outside ofthe filler tube to enable it to be withdrawnfrom the tank filler neck.11. With assistance from a second personsupporting the fuel tank, remove the four tankfixings.3.**f .,‘..‘-’ ,,., :>..:..CAUTION: Before disconnecting any part of thefuel system it is imperative that all dust, dirt anddebris is removed from around the componentsto prevent ingress of foreign matter into the fuelsystem..,,‘Y.:,....‘.‘_,. .’: ”; ‘:: ”..,.’1.2.3.4.5.6.Drive the vehicle onto a suitable hoist.Depressurize the fuel system. (seedepressurizing procedure-page 34)Disconnect the battery negative terminal.Disconnect the electrical leads to the fuel tanksender unit. Disconnect the fuel pumpelectrical multiplug, access to which is gainedthrough the left hand rear wheel arch, theplug is located between the underside of thebody and chassis side member.Raise the hoist.Remove the drain plug from the bottom of thefuel tank and drain the fuel into a suitablecontainer that can be sealed afterwards.ENSURE THAT THE TANK IS DRAINEDCOMPLETELY.Refit the drain plug (refer to Warningconcerning fuel handling at start of thisprocedure.From underneath the vehicle7.8.9.Disconnect the fuel hose from the inlet sideof the fuel filter.Disconnect the fuel return pipe to the fueltank.Remove the breather hose and threeevaporative loss hoses from the fuel tank, sealall hose and pipe openings to prevent ingressof foreign matter.12.13.14.Refitting15.16.17.Tilt the left hand side of the tank downwardsand maneuver it out of the chassis frame. Careshould be taken to ensure that the fuel feedpipe to filter is not damaged when loweringthe tank.Place the tank in a safe area and ensure that allnecessary precautions are undertaken to makeall personnel within the vicinity aware that thetank will give off residual fuel fumes.If necessary remove the fuel pump from thetank. (See Fuel Pump remove and refit).Refit the fuel tank to the chassis, taking careto relocate the fuel feed pipe grommetsbetween the fuel tank and chassis.Reverse the removal procedure, ensuring thatthe sealing ring. fuel line and hoseconnections are secure. I(Run the engine and re-check all connectionsto ensure no fuel leaks exist. Reverse theremaining removal procedure. Recode theradio.‘l..,RRPOIOE3 8 REVISED: SEPT. 90


FUEL INJECTION SYSTEM iI-9 1FUEL PUMPRemove and refitRemovingWARNING: Ensure that the Fuel HandlingPrecautions given in Section 01 - Introductionregarding fuel handling are strictly adhered towhen carrying out the following instructions.1. Drive the vehicle onto a suitable hoist.2. Depressurize the fuel pump system. (seedepressurizing procedure-page 34)3. Disconnect the battery negative terminal.4. Remove the fuel tank from the chassis frame.(see fuel tank remove and refit-page 38)5. Place the tank in a safe area.6. Disconnect the fuel supply hose from thepump.7. Remove any previous sealant from the top ofthe pump flange.8. Remove the five screws and withdraw thepump from the tank.Refitting9. Clean the immediate area around the pumpopening in the fuel tank.10. Fit a NEW pump seal.11. Secure the pump to the tank and tighten thescrews securely.12. Liberally coat the heads of the screws andflange of the fuel pump with Sikaflex 221flexible adhesive sealant.13. Reverse the removal procedure, ensuring thatthe sealing ring, fuel line and hoseconnections are secure. Recode the radio.14. Run the engine and re-check all connectionsto ensure no fuel leaks exist. Reverse theremaining removal procedure.ContinuedREVISED: SEPT. 90 39


FUEL INJECTION SYSTEMKANGE1987-91 ROVERFUEL PIPESWARNING: Depressurize fuel system beforedisconnecting any of the fuel pipes and ensurethat all necessary precautions are taken againstfuel spillage.KEY1. Fuel feed hose to fuel rail.2. Fuel return hose to fuel tank.3. Rigid fuel feed pipe.4. Rigid fuel return pipe.5. Fuel filter.6. Rigid fuel feed pipe to filter.7. Breather hose.8. in-tank fuel pump.9. Fuel filler neck.10. Fuel tank.RRPOISEREVISED: SEPT. SO


;;^d;& 1989FUEL INJECTION SYSTEM 11%) 1I’I-+361262629423106243465332114‘,1UPNOAF32884E I SVFUEL INJECTION - Circuit Diagram - 1989 Model YearI1. 40 way connector to Electronic Control Unit(ECU).2. Lambda sensor (left side - bank A).3. Lambda sensor fright side - bank 6).4. By-pass air valve (stepper motor) (fast idle).5. Lambda sensor screened ground.6. Fuse 18 - main fuse panel.7. Inertia switch.8. Fuel pump.9. Ignition switch.10. Speed transducer (road speed input).11. Neutral switch (automatic gearbox) (loadinput).12. Main cable connector.13. Battery.14. Diagnostic plug.15. In-line resistor.16. Coil/-ve (engine RPM input).17. Coolant temperature thermistor (sensor)(input).18. Fuel temperature thermistor (sensor) (input).19. Throttle potentiometer.20. Air flow sensor.21. Fuel pump relay.22. Main relay.23. Injectors-l to 8.24. Pick-up point E.F.I. warning symbol (instrumentbinnacle).25. Heated front screen sense.26. Purge control valve.27. 12\/ from fan relay.28. Air conditioning switch sense.29. Air conditioning output co?itrof.30. Air conditioning load input.31. Fan relay feed.32. Heater/air con. cable connector.33. Condenser fan timer control.= = = Denotes screened ground.NOTE: Reference to left and right side is made when viewing vehicle from rear.1ADDITION: SEPT. 88 / REVISED: MAY 89 41


\19 FUEL INJECTION SYSTEMRANGElg8’ ROVERFUEL INJECFION SYSTEMFor 1989 model year, the EFI system has a Lucas14CU electronic control unit. This is a developmentof the 13CU used on 3.5 litre vehicles.In most respects the 14CU works in the same wayusing the same engine components, it doeshowever have additional capacity, enabling it tocontrol fuel tank vapour purging and airconditioning.CONTINUITY TEST PROCEDURETest procedure using a multi-meter is carried out asfor 13CU, with the addition of tests for the purgecontrol valve, air conditioning, heated front screenand condenser fan inputs.The use of a hand held vacuum pump, for examplea ‘Mityvac’, is required to carry out Tests 9 and IO.Note that the 40 way multi-plug to the ECU iswired as in the following table.Condenser fansPIN NOS.CABLE COLOURIt should be noted that under high coolanttemperatures, when the engine is switched off, thecondenser fans will be activated and will run forapproximately ten minutes.Throttle potentiometerA further improvement is the fitting of a ‘selfadaptive’ throttle potentiometer. This means thatadjustment of the throttle potentiometer is nolonger possible. It also means that thepotentiometer setting is not lost, for example,when throttle stop wear occurs.Purge valveThe operation of the charcoal canister purge valveis checked during the fuel injection system test. SeeTESTS 9 and 10 Section 19, page 48.Recommended equipmentThe diagnostic equipment used for checking outthe l4CU system is the same as that used forI~CU, with the addition of a new memory card forthe Hand held test unit.14CU Memory cardLucas Part Number - 547465001. Redigreen2. Brown/orange3. Yellow4. Black5. Black/white6. Yellow7. Green/blue8. Purple/yellow9. White/light green10. Black/Yellow11. Yellow/white12. Blue/red13. Yellow/blue14. Black15. Brown16. Blue/purple17. Grey/yellow18. White/pink19. Whitelgrey20. Red21. Yellow/black22. Blue/red23. Blue24. Blue25. Red/black26. Green/white27. BlackIgrey28. Blue/grey29. Orange30. Not used31. Not used32. Creylwhite33. Black/grey34. Black/orange35. Blue/green36. Black/green37. White/yellow 438. Not used39. White/black40. BlackThe last colour denotes the wire tracer colour.4 2 ADDiTlON: SEPT. 88 / REVISED: MAY 89


K”d;‘;rt 1989FUEL INJECTION SYSTEMTESTS - Using a Multi-Meter - 14CU system - Key to SymbolsThe following continuity tests are intended as a guide to identifying where a fault may be within a circuit;reference should be made to the fuel injection circuit diagram for full circuit information.ELECTRONIC CONAND MULTIPLUGCONNECTIONPUMP RELAYFUEL PUMPROAD SPEEDINPUT (SPEEDTRANSDUCER)TEMPERATUREPOTENTIOMETERHOT WIRE AIRFLOW METERADDITION: SEPT. 88 / REVISED: MAY 89 43


l-1 19 FUEL INJECTION SYSTEM1989 t(ANbtROVERNOTE: Ail tests are carried out from the electronic control unit (ECU) harness multi-plug unless statedotherwise in the test procedure.‘EST PROCEDURE. Check battery supply to ECURESULTS - Check cables and units shown in boldVoltmeter reading of batten/ volts -(mimimum battery voltage IO volts)Proceed to Test 2Voltmeter reading of zero voltsCheck:-..’,.. 1IGNITION OFF,.’ .TEST PROCEDURE2. Check ignition supply to ECURESULTS - Check cables and units shown in boldRR262OE01 1 /Voltmeter reading of battery volts -(minimum battery voltage 10 volts)Proceed to Test 3Incorrect reading check:--mI-’ I ’IGNITION ON44 ADDITION: SEPT. 88 I REVISED: MAY 89:.


k”d;‘ir; 1989rEST PROCEDUREI. Check operation ofMain relayFUEL INIECTION SYSTEM 119 1RESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Proceed to Test 5I -4Voltmeter reading of zero volts -Proceed to Test 4IJ\ 1 /-aIcl’ I \IGNITION ON1. Fault Diagnosis Voltmeter reading of battery voltMain relay circuitsIGNITION OFFContinuedADDITION: SEPT. 88 ! REVISED: MARCH SO 45


.. I1191 FUEL INJECTION SYSTEMCheck1989 K”d;;;F1!i.rEST PROCEDURE 1 RESULTS - Check cables and units shown in boldengine speed signal Voltmeter reading of 9.5 volts + 1 voltCable and resislor Proceed to Test 6Voltmeter reading of zero voltsCheck:-.’..:‘.RR2631E1 1 /-a-’0I ’IGNITION ON:.p-EST PROCEDUREi. Check operationof pump relayRESULTS - Check cables and units shown in boldTest lamp will illuminate for approximately1 second when ignition is switched onIf 0.K - Proceed to Test 8Lamp does not illuminateCheck:-If OK proceed to Test 8.’RR2632EIGNlTtON ON4.,;. .‘.,1,:.:,.,’‘,: ,.:46 ADDITION: SEPT. 88 / REVISED: MARCH 90


FUEL INJECTION SYSTEM 119 1TEST PROCEDURE7. Fault diagnosisPump relay circuitsRESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Suspect ECUVoltmeter reading of zero voltsCheck:-RR2833EIGNITION ONTEST PROCEDUREI. Check operation of Fuel pumpNOTE: II is not possible to place themulti-meter probes directly onto thepump lerminals. A link lead attachedlo the pump is accessible behind therear left hand wheel located betweenthe chassis and stowage area floorpanel.RESULTS - Check cables and unhs shown in boldVoltmeter reading of battery volts -Pump operating - Proceed to Test 10(A)Voltmeter reading of batteryvolts -Pump not operatingCheck:-., -.KEY:1. Inertia switch2. Fuse 18(B)Voltmeter reading of zero voltsCheck:-:IGNITION ONRR2634E:Continued1,‘.ADDITION: SEPT. 88 I REVISED: DEC. 88


1191 FUEL INJECTION SYSTEM 1989 Tv\IYUC.-- P(\VFRIm.v . L..ITEST PROCEDURERESULTS - Check cables and units shown in bold9. Check purge valve. Part 1 - seating Vacuum should hold for 2.5 minutes1. Disconnect pipe from purge valve lo If vacuum correct proceed to test 10plenum (al plenum)2. Connect vacuum pump to pipe to purgeIf vacuum incorrect check:valve3. Apply vacuum of 2.5 in/Hg-_30 I -IGNITION OFF9R2212ETEST PROCEDURE10. Check purge valve. Part 2 - operation1. Apply vacuum - 2.5 in/Hg, switchignition on2. Connect pins 16 and 17 to earth toenergise pump relay.RESULTS - Check cables and units shown in boldVacuum should be releasedIf OK proceed to test 11If vacuum not released check:RR2OlSE-m-0’ I ’IGNITION ON.._\.II. . .:. .;48 ADDITION: SEPT. 88 / REVISED: DEC. 88


R”d;;;i 1989FUEL INIECTION SYSTEM 119 1rEST PROCEDURERESULTS - Check cables and units shown in bold‘.* .1Il.Check injectors,Injector circuitOhm-meter reading of 4-4.5 Ohms -Proceed to Test 12” ,Ohm-meter reading of 5-6 Ohms -Suspect 1 injectorOhm-meter reading of 8-9 Ohms -Suspect 2 injectorsPin 13 left bank ‘A’ injectors 1,3,5,7). Ohm-meter reading of 16-17 Ohms -Suspect 3 injectorsCheck for open circuit injector(s) or wiring faults.Ohm-meter reading of InfinityCheck:IGNITION OFFRR2535EI-EST PROCEDURERESULTS - Check cables and units shown in bold.,”12. Check injectors,Injector circuitOhm-meter reading of 4-4.5 Ohms -Proceed to Test 13IPin 11 rightbank ‘B’ injectors 2,4,6,6)Ohm-meter reading of 5-6 Ohms -Suspect 1 injectorOhm-meter reading of 8-9 Ohms -Suspect 2 injectorsOhm-meter reading of 16-17 Ohms -Suspect 3 injectorsCheck for open circuit injector(s) or wiring faults.Ohm-meter reading of InfinityCheck::’; :’,.(. .‘.;:. .: .::F.‘,. .‘. ,:IGNITION OFFI.L”““bContinuedADDITION: SEPT. 88 / REVISED: DEC. 88 49”


1191 FUEL INIECT’ION SYSTEM1989 k”d;\;;i..:reading-temperature to.‘i,‘. . .. . .,: 0ature Conversion.:..X::IGNITION OFF.50 ADDITION: SEPT. 88 / REVISED: DEC. 88


FUEL INJECTION SYSTEM 119 1Temperature ConversionShould beOhms9100 - 93005700 - 5900IGNITION OFFContinued,::ADDITION: SEPT. 88 51


l-i 19 FUEL INJECTION SYSTEMMT PROCEDURE15. Check air bypass valve - Par( 1RESULTS - Check cables and units shown in boldOhm-meter reading of 40-60 Ohms -Proceed to Test 16Incorrect readingCheck:-IGNITION OFF‘EST PROCEDURE16. Check air bypass valve - Part 2RESULTS - Check cables and units shown in boldOhm-meter reading of 40-60 Ohms -Proceed to Test 17Incorrect readingCheck:-I0IWMOE52 ADDITION: SEPT. 88


,.;__.iEST PROCEDURE17. Check throttle potentiometer - Part IRESULTS - Check cables and unils shown in boldOhm-meter reading of 4000-6000 Ohms -Proceed to Test 18Incorrect reading of InfinityCheck:-17KiNlTlON OFF:_ ,’IW641EThrottle closed: 0.085-0.545 volts) smooth) swing) betweenRR2642EContinuedADDITION: SEPT. 88 ! REVISED: MAY 89 53


.,‘i,.:‘. ‘,I,ITEST PROCEDUREIS.Check output ofAirflow sensorRESULTS - Check cables and units shown in boldVoltmeter reading of 0.2-0.7 volts-Proceed to Test 20Incorrect voltmeter readingCheck:-.:.’TIGNITION ON..:j.’(’ :‘..,. ..>.s (... ‘._,,: .,,.’ ::‘.::.‘.’?.IR2f343EPRECAUTION:Depressurize the fuel system when fitting the fuel pressure gauge or disconnecting/replacing fuel systemcomponents.CAUTION: Thoroughly clean the immediate area around the fuel filter and hose connections beforedisconnecting the fuel feed line from the filter. Failure to do so could cause foreign matter to bepresent in the fuel system which would be detrimental to the fuel system components.WARNING: The spillage of fuel from the fuel filter is unavoidable when disconnecting the fuel feedline, ensure that all necessary precautions are taken to prevent fire and explosion due to fuel vapourand fuel seepage,DEPRESSURIZING PROCEDURE ‘.aa) Ignition off, pull pump relay off its terminal block.b) Crank engine for a few seconds - engine may fire and run until fuel pressure is reduced.cl Switch off the ignition.d) Connect fuel pressure gauge in the fuel supply line between the fuel rail and the fuel filter, adjacent tothe filter (see Test 20).e) Reconnect the pump relay.’54 ADDITION: SEPT. 88 / REVISED: MAY 89


.“.. .‘C--ROVER lg8’ FUEL INJECTION SYSTEM I19 1‘. 1.1.:.rEST PROCEDURERESULTS - Check cables and units shown in bold10. Check fuel system pressureService tool 18C 1500(A)Expected reading 2,39-2,672 kgf/cm’(34.0-38.0 p.s.i.)NOTE: Insert the pressuregauge in the fuel feed lineimmediately after the fuelline filter. The filter islocated beneath the righthand rear wheel arch attachedlo the chassis(B)Pressure drop-max 0.7 kgf/cm2(10 p.s.i.) in one minuteProceed to Test 21:IQNITION ON0I -IGNITION OFFRR2644E--ContinuedADDITION: SEPT. 88 / REVISED: MAY 89 55


-l 19 FUEL INJECTION SYSTEM1989 wiNCltROVEREST PROCEDURERESULTS - Check cables and units shown in bold.,,,’ :’!l.Check for leaking injectorNOTE: Before removing anyof the injectors, remove andexamine the spark plugs,check for consistentcolouralion of plugs.A leaking injector willresult in the appropriatespark plug being ‘sooted up’.WARNING: Ensure that allnecessary precautions are takento prevent fire and explosion.Replace any injector which leaksmore than 2 drops of fuel per minute.Remove all injectors frommanifold but do notdisconnect from fuel railIGNITION ONRR2648E‘EST PROCEDURE12. Check for injector operationLeft bank ‘A’ injectors 1,3,5,7RESULTS - Check cables and units shown in boldWARNING: Ensure that allnecessary precautions are takenIO prevent fire and explosion.Repeat test for other injectorsReplace any injector which does not operate.NOTE: Fuel flow is 160-175 cc (using white spirit)or 180-195 cc fusing petrol) (minimum)per minute per injector, al 2.54 kgflcm’ (36.25 psi)system pressure at 20% 2 2°C. . . .IIR2646EIGNITION ON56 ADDITION: SEPT. 88 / REVISED: MAY 89


k”d;;r; 1989‘EST PROCEDURE!3. Right bank ‘B’ injectors 2,4,6,8FUEL INJECTION SYSTEM 119 1RESULTS - Check cables and units shown in boldWARNING: Ensure that aIfnecessary precautions are takenIO prevent fire and explosionRepeat test for other injectorsReplace any injector which does not operateNOTE: Fuel flow is 160-175 cc fusing mineral spirils)or 180-195 cc (using gasoline) (minimum) per minuteper injeclor, al 2.54 kghcm’ (36.25 psi) systempressure at 20°C + 2°CRRz64R‘; ,, 3\I\,.QIJ’8\ 1 /-aI-0’ I ’IGNITION ONrEST PROCEDURE14. Check gear switch inputRESULTS - Check cables and unils shown in boldVoltmeter reading of zero volts-Neutral and parkVoltmeter reading of 2.5-5.0 Volts-R.D.3.2.1 - Proceed to Test 25Incorrect readingCheck:IGNlTlbN ONRR2646EADDITION: SEPT. 88 / REVISED: SEPT. 90 57


l-l 19 FUEL INJECTION SYSTEMrEST PROCEDURE15. Check road speed inputNOTE: Raise and rotate the left handteat road wheel slowly1989 ;;^o”v‘;r;RESULTS - Check cables and units shown in boldVoltmeter reading of 0 to 12V fluctuating 6 times perrevolution - Proceed to Test 26Incorrect readingCheck:. .:.‘,0\ 1 /- - - -’ I ’IGNITION ONRRw4aEVOTE: Remove pump relay from its connector..).::..i .;.(.....,,:,.IGNITION OFF. . . c’58 ADDITION: SEPT. 88 / REVISED: SEPT. 90:. .‘.. :I


FUEL INJECTION SYSTEM 119 1rEST PROCEDURE16a. Check Lambda sensor supplyA. LH Lambda sensor6. RH Lambda sensorRESULTS - Check cables and units shown in bold ’Correct Vl and V2 - 12 voltsProceed to Test 26bIncorrect readingCheck:0I-IGNITION OFFRA2707ErEST PROCEDURE26b. Check Lambda sensor operationNole: Select ‘P’ in main gearbox and run engine at1000 revlmin, normal operating temperatureA. LH Lambda sensorB. RH Lambda sensorRESULTS - Check cables and units shown in boldCorrect 0.5OV - l.OOV fluctuatingIncorrect 0.050 V - Check: Air leaks, faulty orcontaminated injectors, low fuel pressure - if OK fitnew Lambda sensorIncorrect l.OOV - Check: High fuel pressure, leakinginjectors, saturated carbon canister - if OK fit newLambda sensor.-AaL TRR2708EADDITION: SEPT 88 / REVISED: SEPT. 89 59


1191 FUEL INJECTION SYSTEM1989 k”d;;i;i,;. ”‘EST PROCEDURE!7. Check air conditioning thermostat input27NOTE: Select air conditioning positionand move thermostat switch to coldKEY:1. Fuse 82. Air conditioning switch3. Air conditioning thermostat4. High pressure switch - air conditioning5. Compressor clutch relayRESULTS - Check cables and units shown in boldVoltmeter reading of battery volts -Proceed lo Test 28Incorrect readingCheck:IR2651ENOTE: Select heater fan speed I. II or IllKEY:1. Fuse 6kRZOS2E60 ADDITION: SEPT. 88 / REVISED: SEPT. 89; ..‘. . .


KAl~bJrROVER “*’ FUEL INIECTION SYSTEM 119 1I ITEST PROCEDURE29. Check operation ot compressor clutch relayRESULTS - Check cables and units shown in boldVoltmeter reading of 12 volts -Proceed to Test 31NOTE: Select air conditioning position,Incorrect reading of zero voltsthermostat cold, and tan speed I, II, or Ill Proceed to Test 3030. Fault diagnosis - compressor clutch relay r reading of 12 volts -NOTEz Select air conditioning position,thermostat cold, and tan speed I, II or IllKEY:1. Compressor clutch relay2. Compressor clutch3. High pressure switch4. ThermostatContinuedADDITION: SEPT. 88 / REVISED: DEC. 88 61‘.’ ‘.y:...


1191 FUEL INJECTION SYSTEM1989 ;;^d;&EST PROCEDURERESULTS - Check cables and units shown in boldIIl.Check heated front screen inputNOTE: Engine running, heated front screenswitched ‘ON’KEY:1. Oil pressure switch2. Front screen timer unit3. Front screen switchVoltmeter reading of 12 volts -Proceed to Test 32Incorrect reading of zero voltsCheck:rEST PROCEDURE12. Check operation of condenser fan outputDisconnect coolant temperature sensor and fueltemperature sensor and bridge plug connectorsRESULTS - Check cables and units shown in boldVoltmeter reading of 12 volts - end of testsVoltmeter reading of zero voltsProceed lo Test 33NOTE: Switch ignition ‘ON’ for 5 seconds, switchignition ‘OFF’The fan timer will operate the fans forapproximately 10 minutes unless it is disconnectedKEY:1. Condenser fan timer2. Condenser fan relayRR2660E62 ADDITION: SEPT. 88 / REVISED: DEC. 88


. ..‘;..L.,::.,’X‘EST PROCEDURE13. Fault diagnosis - condenser fan outpulFUEL INJECTION SYSTEM 119 1RESULTS - Check cables and units shown in boldVoltmeter reading of 12 volts -Suspect ECUIncorrect readingCheck:KEY:1. Condenser fan timer2. Condenser fan relay3. Fuses Al and A24. Condenser fans\ 1 /-a-0’ I ’IGNITION ONIR 2676EAfter completing the tests with either the ‘Diagnostic’ equipment or multi-meter, re-test the vehicle to ensurethe faults have been rectified. If faults still persist, recheck using the Lucas diagnostic equipment.,ADDITION: SEPT. 88 I REVISED: SEPT. 90 63


1 2 BA6IEov-RWOlOEl-BGWG4N .+---t B3IBNI 9 I- - -BR,, ,. :’Condenser fan circuit diagram RR2610ECondenser fans/Condenser fan timer1. 12V from EFI main relay.Check operation2. Condenser fan timer unit.3. Fan relay. 1. Start engine.4. 12V battery feed. 2. Move air con/heater control to air conditioning5. Trigger, from ECU.position.6. 12V from fan relay. 3. Check condenser fans, if working the7. Fuse Al-20 amp.condenser fan relay and wiring to the fans is8. Fuse A2-20 amp.functioning.9. Fan motors 4. If not working check fuses Al and A2, and thevoltage between connections 86 on fan relayand earth. If 12 volts is not present, checkwiring back to air con switch.5. If 12 volts is present, but fans NOT working,short out connections 30 and 87 on fan relay.If fans work fit new relay. If fans NOT working,check supply to fan relay from main harness.6. Apply a 12 volt supply for at least two secondsto connection 5 on fan timer within SIXSECONDS of switching engin off. Thecondenser fans should run for 9.f minutes +0.5 minutes, and switch off.7. If the fans do not work after applying voltageto timer, short out connections 4 and 8 on fantimer, if fans work fit new fan timer. If fans donot work, check wiring.64 ADDITION: SEPT. 88 / REVISED: SEPT. 90


KANbtROVER lg8’FUEL INJECTION SYSTEMOVERHAUL THROlTLE LEVERS AND THROTTLEVALVE - 3.9 V8 ModelPreparation, remove, overhaul and refitPreparation1.2.3.4.8.9.10.Disconnect the battery negative terminal.Disconnect the electrical multi-plug from thebypass air valve (stepper motor).Disconnect the small vacuum hose at the rearof the plenum chamber, located below thebypass air valve.To assist re-assembly mark an identificationline on the throttle cable outer coveringdirectly behind the adjustment thumb wheelbefore disconnecting the throttle cable fromthe throttle lever.Remove the cotter pin and clevis pin securingthe throttle cable to the lever.Carefully pry the adjustment thumb wheelfrom the throttle bracket. Lay the cable aside.Release the retaining clip from the kick downcable and remove the clevis pin.To assist re-assembly apply adhesive tapebehind the rear adjustment nut on the kickdown cable outer sleeve to prevent the nutmoving out of position.Release the front lock nut and remove it fromthe outer sleeve to enable the cable to beremoved from the throttle bracket. Lay thecable aside.Remove the vacuum hose from the cruisecontrol actuator.11. Remove the large hose from the neck of theplenum chamber.12. Disconnect the multi-plug to the throttlepotentiometer.13. Remove the PCV breather hose.14. Disconnect the two coolant hoses in turn andimmediately plug the end of each hose toprevent excessive loss of coolant. Identifyeach hose for re-assembly.15. Remove the distributor vacuum hose.16. Release the two screws and remove thepotentiometer.ADDITION: SEPT. 88 65


7 6RR2400EKEYI. Spherical bearing2. Retaining clips (2)3. Countershaft assembly4. Overtravel spring5. Throttle spindle nut6. Throttle return spring (2)7. Tab washer8. Throttle stop lever9. Throttle bracket assembly10. Pop rivets (2)21. Bend back the the tabs of the lock washer.22. While holding the throttle stop lever in theclosed position, release the nut until it is freeof the throttle valve shaft.23. Release the tension on the outboard throttlereturn spring.24. Unhook and remove the over-travel spring.Remove throttle lever assembly17.18.19.20.Remove the six screws securing the plenumchamber to the ram housing. Lift off theplenum chamber.Remove the hose from the air bypass valvehousing and plenum chamber air inlet pipe.Unclip the cruise control actuator link. Whileholding the throttle valve fully open releasethe link from the countershaft assembly.Carefully return the lever assembly to theclosed throttle position.Release the tension on the inboard throttlereturn spring and slide the spring along thecountershaft assembly to give access to thethrottle shaft nut.66ADDITION: SEPT. 88‘. . . .


:FUEL INJECTION SYSTEM25. Remove the three bolts securing the throttlebracket to the plenum chamber and withdrawthe bracket assembly.26. Remove the tab washer and throttle stop leverfrom the throttle valve shaft.31.32.Pre-grease a new bush with Admax L3 orEnergrease LS3 assemble the bush into thebearing retaining plates and pop-rivet theassembly to the throttle bracket with two 4.7mm (3116 in) diameter domed head rivets 9mm (0.361 in) long.Examine the bearing surface of thecountershaft assembly. If worn fit a newassembly, otherwise wind the throttle returnspring off the levers.32.tInspect and overhaul throttle lever assembly27.28.29.30.Remove the two retaining clips from eitherside of the spherical bearing.Remove the countershaft assembly from thebearing.If the spherical bush appears to be worn,dismantle as follows. Using a 4,7 mm (3116 in)diameter drill, drill out the two pop rivetssecuring the spherical bearing to the throttlebracket assembly.Split the bearing assembly and discard thebearing bush.RR2308E33. Wind a new spring onto the countershaftassembly noting that the small hooked end ofthe spring is wound on first.RR2309E-RR2307E ‘9’ .34. Pre-grease the shaft with Admax L3 orEnergrease LS3 and fit the countershaftassembly to the spherical bearing and securewith the two clips.35. Examine the throttle stop lever ior wear, fit anew lever if necessary. ’,,,::Continued:ADDITION: SEPT. 88 67


Inspect and overhaul throttle valve36.37.Examine the throttle valve shaft for excessivewear between the bearing bushes in theplenum chamber and the shaft. A smallamount of clearance is permissible. Ifexcessive wear is evident fit new shaft andbushes as follows.Remove the two split screws securing thethrottle valve disc and withdraw the disc,taking care not to damage the shaft.mI 8RR2402EI.’,41.42.43.Fit the throttle valve shaft and disc, secure inposition with the two split screws. Do not fullytighten the screws at this stage.Rotate the throttle shaft 360” once or twice tocentralise the disc in the bore. Tighten thetwo screws.Rotate the shaft until the split end of thescrews are accessible. Using the blade of ascrew driver spread the split to secure thescrews in the shaft..‘(,FIR24iIOE KQ I-38. Remove the shaft and air seal from the plenumchamber.RR2409ERR2401E39. Using a suitable drift, drive out the bushestaking care not damage the bores in theplenum chamber.40. Press in new bushes until they are flush withthe throttle valve bore.44. Pre-grease a new air seal with Admax L3 orEnergrease LS3. Fit the seal pushing it downthe shaft and into the counterbore until theseal is 6.0 mm (0.236 in) below the face of theplenum chamber.JCAUTION: Ensure that the bushes do notprotrude into the bore as they will interferewith the movement of the throttle valvedisc.. .68 ADDITION: SEPT. 88


FUEL INJECTION SYSTEMAssemble throttle levers and bracket45.46.47.40.49.50.51.52Fit the stop lever to the throttle valve shaftfollowed by a new tab washer and secure withthe interconnecting nut.Holding the stop lever on its stop, tighten theinterconnecting nut securely and bend overthe tabs of the tab washer to lock the nut inposition.Fit the inboard throttle return spring notingthat the small hooked end of the spring isnearest the plenum chamber.Locate the hooked end of the inboard springon the stop lever and wind up the straight endone full turn and anchor it in the appropriateslot.Fit the countershaft to the interconnecting nutof the throttle valve shaft.Fit the throttle bracket assembly and securewith the three retaining bolts.Ensuring that the hooked end of the outboardspring is anchored by the lever, wind thespring up one full turn and locate the free endin its appropriate slot.Fit the over-travel spring.Lightly grease the throttle return and over-travelsprings with Admax L3 or Energrease LS3.53.54.Using a depth vernier or depth micrometerfrom the mouth of the bore check the topand bottom of the valve disc. The disc mustbe within 0.5 mm (0.019 in) total indicatorreading across the full diameter of the disc.If the throttle disc is out of limits adjust thesmall set screw below the stop lever. Accessto the screw is gained from the bottom of theplenum chamber neck adjacent to the throttlelevers support bracket.50 46 48Refitting55. Reconnect and adjust the cruise controlactuator link. (See cruise control-actuator linksetting)56. Clean any previous sealant from the joint faceof the plenum chamber and ram housing.Apply ‘Hylomar’ sealant to the faces and refitthe plenum chamber. Tighten the bolts to thecorrect torque value-see section 06.57. Reverse the remaining preparation instructions.NOTE: If new throttle levers have been fitted theminimum throttle setting of the disc must bechecked to ensure that it is SO” to the bore.ADDITEON: SEPT. 88 / REVISED: MARCH SO 69.:,


ELECTRONIC FUEL INJECTION-RELAYSIncorporated in the fuel injection electrical systemare two relays which are located beneath the frontright hand seat adjacent to the cruise control relayand emission maintenance reminder. Access to therelays is gained through the opening at the bottomof the seat when the seat is in its fully forwardposition on the seat slides.1. Fuel pump relay (mounted on a blue terminalblock).2. Main relay (mounted on a black terminalblock).3. Diagnostic plug.4. Condenser fan timer unit.ELECTRONIC CONTROL UNIT (ECU)-14 CUNOTE: The ECU is not a serviceable item. In theevent of a unit failure the ECU must be replaced.Remove and refitRemoving1.2.3.4.5.6.7Remove the front and side seat base trim ofthe front right hand seat.Adjust the seat to its most rearward positionand raise the seat cushion height to allowaccess to the ECU fixings.Disconnect the battery negative terminal.Release the ECU plug retaining clip.Maneuver the front of the plug (in thedirection of the bold arrow) and detach theother end of the plug from the retaining peg. .Release the two screws securing the ECU tothe mounting bracket.Withdraw the ECU from the spring clip andremove it from the vehicle.RR2555ERemove and refitRemoving1. Disconnect the battery negative terminal.2. Pull the relay(s) from the terminal block(s).Refitting3. Reverse the removal procedure.,‘/RR2667SRefitting8. Refit the ECU securely in the spring clip and fitand tighten the two screws.9. Reconnect the ECU harness plug. Ensure thatthe plug is pushed firmly into its location andthat the retaining clip secures the plug inposition.10. Remove remaining removal procedure.70 ADDITION: SEPT. 88 / REVISED: MARCH 90


.., _. . --ROVER lyy”26282942.310621lV”B I. I II, YBI’ WG-3011252791s:. ”,,3630191622535203327223917RR2 955EFUEL INFECTION - Circuit Diagram - 1990/91 model vear1. 40 -way connector to Electronic Control Unit(ECU).2. Lambda sensor (left side - bank A).3. Lambda sensor (right side - bank 8).4. By-pass air valve (stepper motor) (fast idle).5. Lambda sensor screened ground.6. Fuse C4 - main fuse panel.7. Inertia switch.8. Fuel pump.9. Ignition switch.10. Speed transducer (road speed input).Il. Neutral switch (automatic gearbox) (loadinput).12. Main cable connector.13. Battery.14. Diagnostic plug.15. In-line resistor.16. Coil/-ve (engine RPM input).18. Fuel temperature thermistor (sensor) (input).19. Throttle potentiometer.20. Air flow sensor.21. Fuel pump relay.22. Main relay.23. Injectors-l to 8.24. Pick-up point E.F.I. warning symbol (instrumentbinnacle).25. Heated front screen sense.26. Purge control valve.27. 12\’ from fan relay.28. Air conditioning output co@trol.29. Air conditioning load input.30. Fan relay feed.31. Tune resistor (early vehicles).32. Heater/air con. cable connector.33. Condenser fan timer control.34. Fault display input.1 i. Coolant temperature thermistor (sensor) = = = Denotes screened ground.(input).NOTE: Reference to left and right side is made when viewing the vehicle from the rear.ADDITION: SEPT. 89/REVISED: SEPT. 90 71


FUEL INJECTION SYSTEM1990 KANCltROVERELECTRONIC FUEL INJECTION-LUCAS 14CUX SYSTEM17EM FAULT CODE DISPLAY UNIT - RR2814h-l1990 model year vehicles have an enhanced fuelinjection system, using a Lucas 14CUX electroniccontrol unit, The system is a development of the14Cu sytem introduced on 3.9 litre vehicles.The system works in the same way, newcomponents being a tune select resistor and a faultcode display unit.TUNE SELECT RESISTOR - RR281 1MRd28llMThe 14CUX system is used in various markets, but acommon ECU is used. To suit individual marketrequirements a tune select resistor is connectedacross pins 5 and 27 of the ECU.It is located adjacent to the ECU, and strapped tothe EFI cable assembly. The value of the resistor isdependent on the market application.NOTE: For USA market models the resistor valueis 3900 Ohms, wire colour, white.NOTE: Vehicles after VIN No 451518 are fittedwith a new ECU, Part No. PRC 8747 to replacePRC 7081. This ECU no longer requires the tuneselect resistor, which is therefore deleted. Faultcode 21 is no longer stored by the ECU.1990 model year vehicles have a fault code displayunit which is located underneath the right handfront seat, adjacent to the EFI ECU. The unit willdisplay the relevant fault code, in addition to theEFI warning light being illuminated.NOTE: Fault code 59 will NOT be indicated bythe EFI warning light.Recommended equipmentThe diagnostic equipment for checking out the14CuX system is the same as that used for 14CU,with the addition of two new memory cards forHand Held Tester.14CUX Memory cards, Lucas Part Number:- 606 01 379.CONTINUITY TEST PROCEDURENOTE: The continuity test procedure for 14CUXsystems is similar to that for 14CU. Note theaddition of the tune select resistor test and thedeletion of Test 28, which does not apply to14CUX systems.(’,‘.‘:. rt". 'iv'. ..>...'I...a .;“.i7 2 ADDITION: SEPT. 89iREVISED: SEPT. 90. . . . t” ;._.,.


K"i;;‘;ir 1990 FUEL INJECTION SYSTEM 119 1.TESTING27Release the ECU plug retaining clip andremove the plug from the ECU. Access isgained by removing the front seat base trim ofthe right hand front seat.Remove the plug shroud and manoeuver italong the harness until there is enoughclearance to enable meter probes to beinserted into the back of the plug.There are six pin numbers 1, 13, 14, 27, 28and 40 moulded onto the rear of the plug asshown in the illustration below, for clarity theelectrical leads have been omitted.Pins 1 to 13 bottom row.Pins 14 to 27 centre row.Pins 28 to 40 top row.28 40-14CONNECTIONS TO 40 WAY CONNECTORPIN Nos. CABLE COLOUR1. Red/green2. Brown/orange3. Yellow4. Blak5. Grey/Black6. Yellow7. Green/blue8. Purple/yellow9. White/light green10. Black/yellow11, Yellow/white12. Blue/redI 3. Yellow/blue14. Black15. Brown16. Blue/purple17. Grey/yellow18. White/pink79. White/grey20. Red21. Yellow/black22. Blue/red23. Blue24. Blue25. Red/black26. Green/white27. Black/grey28. Bluelgrey29. Orange30. Pink31. Black/green32. Creyhvhite33. BlackIgrey34. Orange/black35. Blue/green36. Black/green37. Not used38. Brown/pink39. White/black40. BlackThe last colour denotes the wire tracer colourADDITION: SEPT. 89!REVISED: SEPT. 90 73.


Tune select resistor testlt is recommended that this test is carried out NOTE: This test is not required on vehicles afterbefore Test 1. of Continuity Test Procedure, Section VIN No 451518, which are no longer fitted with a19, page 44. tune select resistor.FUNE SELECT RESISTOR TESTKEY 1) Tune select resistorDescription of fault codesThe fault codes are listed in order of priority. Wheremore than one fault exists, clearing the first faultcode will permit the next code to be displayed.Code 29 - ECU MEMORY CHECK - If this fault isdetected, all other faults are unreliable and musttherefore be ignored.Proceed as follows:‘I ,,NOTE: Fault code 02 will show if the ECU hasjust been reconnected. Switch on ignition toclear the display.Clearing fault code displayIt is necessary to clear the code displayed when thefault has been rectified, and to access any furtherfault codes that may exist. Clear the fault codedisplayed using the following procedure:1. Switch On ignition.2. Disconnect serial link mating plug, wait 5seconds, reconnect.3. Switch OFF ignition, wait for main relay todrop out.4. Switch ON ignition. The display should nowreset. If no other faults exist, and the originalfault has been rectified, the display will beblank.5. If multiple faults exist repeat Steps 1. to 4. aseach fault is cleared the code will change,until all faults are cleared. The display will nowbe blank.1. Leave battery connected2. Switch ignition off3. Wait for approximately 5 seconds4. Disconnect ECU plug5. Re-connect ECU plug6. Switch ignition on and check display unit.NOTE: If fault code 29 is detected again,substitute ECU and restart test sequence.Code 44 - LAMBDA SENSOR A i left bankCode 45 - LAMBDA SENSOR B - right bankIf one of these fault codes is displayed check thewiring to that particular lambda sensor.If both codes are displayed, the volfage supply tothe heater coils of the sensors must be checked.Refer to Test 26, continuity test procedure.Code 25 - IGNITION MISFIRE - This code indicates . . . . .that an ignition system misfire has been detected.ICodes 40 or 50 indicate on which bank the misfirehas occured...’ . . ,,1.,.‘.,..+.‘.._: 3: ‘.,,74ADDITION: SEPT. 89/REVISED: SEPT. 90


FUEL INJECTION SYSTEM.:.:.y. : .:.:$c.Code 40 - MISFIRE BANK A - left bankCode 50 - MISFIRE BANK B - right bankIf both fault codes are displayed check thefollowing components commom to both banks:Distributor capRotor armCoilElectrical connectionsPick-up (air gap)AmplifierInjectors - if code 34 or 36 displayed.If either fault code 40 or 50 is displayed checkcomponents applicable to the particular bank thatthe misfire has occured on:Spark plugsHT leadsDistributor capInjectors - if code 34 bank A or 36 bank 6displayed.Code 12 - AIRFLOW METER - Refer to Test 19,continuity test procedure.Code 21 - FUEL TUNE SELECT - Identifies that thetune select resistor is open circuit - Refer to tuneselect resistor test.Code 34 - INJECTOR BANK A - The display willindicate if the injector/s are causing the engine torun rich or lean.If the bank is running rich, check for:-- faulty injector wiring and connectors- stuck open injectorsIf the bank is running lean, check for:-- faulty injector wiring and connectors- blocked injectorsCode 36 - INjECTOR BANK B - As code 34 exceptrelevant to bank A injectors.Code 14 - COOLANT THERMISTOR - Refer to Test14, continuity test procedure.Code 17 - THROlTLE POTENTIOMETER - Refer toTest 17, continuity test procedure.Code 18 - THROlTLE POTENTIOMETER inputhigh/AIRFLOW METER - low. - Refer to Tests 17,18 and 19 of the continuity test procedureCode 19 - THROTTLE POTENTIOMETER input low/AIRFLOW METER - high. - Refer to Tests 17, 18and 19 of the continuity test procedureCode 88 - PURGE VALVE LEAK - Refer to Test 9and 10 of the continuity test procedure.Code 28 - AIR LEAK - Check for air leaks in thefollowing areas.Hose, air flow meter to plenumBreather system hoses to plenumBrake servo hoseVacuum reservoir hose (fresh air solenoid)Distributor vacuum advanceHose, purge valve to plenumInjector sealsJoint - By pass air valve to plenum- Plenum chamber to ram housing- Ram housing to inlet manifold- Inlet manifold to cylinder headBy pass air valve hoseCode 23 - FUEL SUPPLY - Check fuel systempressure, Test 20 of the continuity test procedure.Code 48 - STEPPER MOTOR - Check base idlespeed - see setting procedure. - Refer to Tests 15and 16 of the continuity test procedure. Checkroad speed sensor - Refer to Test 25 of thecontinuity test procedure.Code 68 - ROAD SPEED SENSOR - Refer to Test25 of the continuity test procedure.Code 69 - GEARSWITCH - Refer to Test 24 of thecontinuity test procedure.Code 59 - GROUP FAULTS 23/28 - This indicatesthat a fault has been registered that is caused bythe fuel supply or an air leak but the exact faultcannot be identified. Check all items outlined undercode 23 and 28.Code 15 - FUEL THERMISTOR - Refer to Test 13 ofthe continuity test procedure.ADDITION: SEPT. 89/REVISED: SEPT. 90


;1990 NINclcROVER..,..’ :,: ;:,:1.i :“. ,: ,:i.‘.’XBASE IDLE SPEED SETTINGNOTE: the base idle speed is set at the factory. Itshould not require further adjustment unless theplenum chamber is changed. The adjustmentscrew is sealed with a plug to preventunauthorised alteration. Check the ignitiontiming before attempting the followingprocedure, since this will affect the idle speed.Equipment requiredTwo blanking hoses. It is recommended that theseare manufactured using a new air by-pass valvehose - Pari No.ETC7874. Cut two equal pieces9Omm (3 l/2 inches) long from the hose and sealone end of each, using 13mm (l/2 inch) diameterbar. A suitable clamp can be used to ensure an airtight sealChecking procedureDrive the vehicle for at least two miles untilthe engine and transmission are hot. Switchoff the engine.Check that all electrical loads are off includingair conditioning.Remove the air by-pass valve hose.Fit the blanking hoses to both the plenumchamber and the air by-pass valve. Ensure thehoses are securely fitted to prevent air leaks.Note that the throttle cable and cruise controlactuator have been omitted from theillustration for clarity.5. Start the engine and check that the idle speedis within the limits specified in Section 05 -Engine Tuning Data.Adjusting base idle speed6. Remove the tamper proof plug that protectsthe idle speed screw. Drill the plug and inserta self tapping screw to enable the plug toextracted.RR2953E7. Start the engine, and using a suitable Allenkey, adjust the idle screw clockwise todecrease or counter-clockwise to increae theidle speed.8. Check fault code display, and clear thememory - see ‘Clearing fault code display’ -section 19, page 74..’ I.,:. .‘,;. : :.76 ADDITION: SEPT. 89:


K”i;;l;i 1990FUEL INJECTION SYSTEM 119 1:..FUEL SYSTEM 1991 MODEL YEARA revised fuel sytem is fitted to 1991 model yearvehicles. The major change is the fitting of a plasticfuel tank with improved breather system. Theremote expansion tank is now deleted.A further improvement is the fitting of a combinedfuel pump and sender unit. A panel in the floor ofthe vehicle permits access to the fuel pump/senderunitFUEL PUMP/SENDER UNITWARNING: Ensure that the Fuel HandlingPrecautions given in Section 01 - Introductionregarding fuel handling are strictly adhered towhen carrying out the following instructions.6. Remove the securing screws and detach theaccess panel from the floor.7. Disconnect the electrical connections at themulti-plug.8. Remove the insulation sealant from around theground lead, and disconnect the ground lead.9. Disconnect the two fuel line unions from thefuel pump.10. Using Special Tool No. LST131, remove pumpassembly retaining ring and withdraw thepump from the fuel tank.WARNING: A quantity of fuel will be retained inthe body of the unit, care must be taken toprevent fuel spillage when the unit is removed.,:::;. ::‘.‘*‘a’.%’CAUTION: Before disconnecting any part of thefuel system, it is imperative that all dust, dirtand debris is removed from around thecomponents to prevent ingress of foreign matterinto the fuel system..,. ,.Special Tool -ringLST131, wrench - pump retaining- LST 144 -‘Speedfit’ disconnectorRemove and refitRemoving1.2.3.4.5.Depressurise the fuel system.Disconnect battery negative lead.Syphon at least 9 litres (2 gallons) of fuel fromthe fuel tank using a suitable container thatcan be sealed afterwards.Remove carpet from loadspace floor andtailgate.Fold back the sound insulation to reveal theaccess panel.ADDITION: SEPT. 89 77


’ FUEL INJECTION SYSTEMRefitting11.12.13.14.15.16.17.18.19.Insert the fuel pump into the tank. Fit theretaining ring and tighten to a torque of 45-50Nm (34-37 Ibf ft).Connect the fuel lines to the pump.Connect the electrical leads at the multi-plug.Connect the ground lead to the pump andinsulate with suitable sealant.When the fuel system has been reassembledcheck all fuel pipes, sealing rings and hoseconnections are secure.Run the engine to check for fuel leaks beforefinal assembly.Inspect the access panel seal, fit a new seal ifnecessary.Fit the access panel and secure to the floorwith the screws.Reverse operations 4 - 5 to refit the soundinsulation and carpet.Remove the insulation sealant from around theground lead, and disconnect the ground lead.Disconnect the two fuel line unions from thefuel pump.Working underneath the vehicle, remove therear anti-roil bar straps, and allow the bar toswing down clear of the tank.FUEL TANKWARNING: Ensure that the Fuel HandlingPrecautions given in Section 01 - Introductionregarding fuel handling are strictly adhered towhen carrying out the following instructions.CAUTION: Before disconnecting any part of thefuel system, it is imperative that all dust, dirtand debris is removed from around thecomponents to prevent ingress of foreign matterinto the fuel system.1'3 11 16RR2962E10.11.12.Remove the tank filler and vent hoses at thefuel tank.Remove the nut and bolt securing the righthand side of the fuel tank strap.Disconnect the WdpOratiVe control pipe at thegreen end of the ‘speedfit’ connector.Remove and refitRemoving1.2.Depressurise fuel system. Disconnect batterynegative lead.Syphon the fuel tank into a suitable containerthat can be sealed afterwards.ENSURE THAT THE TANK IS DRAINEDCOMPLflELY. (refer to Warning concerningfuel vapor and spillage at start of thisprocedure).Remove carpet from loadspace floor andtailgate.Fold back the sound insulation to reveal theaccess panel.Remove the securing screws and detach theaccess panel from the floor.Disconnect the electrical connections at themulti-plug.NOTE: To disconnect the ‘speedfit’ connector,forked end into the two slots of the connectoras shown in the illustation above. Press down onthe collet and simultaneously pull t&e pipe fromthe connector. Special tool LST 144 is availablefor this operation.78 ADDITION: SEPT. 89


:yo;;; 1990FUEL INJECTION SYSTEM,_ :Clamp the inlet and outlet hoses to preventthe minimum of fuel spillage whendisconnecting the hoses.Loosen the two fuel line unions and removethe hoses from the filter canister.Release the single nut and bolt securing thefilter and clamp and remove the filter.‘.’ .,.’13. Remove the back two bolts and nut platessecuring the fuel tank cradle.14. Remove the front nuts, bolts and washers, andremove the fuel tank cradle.15. With the aid of an assistant, tilt the right handside of the tank upwards and manouver thetank through the chassis to remove.RR2966ERefitting,- -\ 7 “Refitting16. Reverse the removal procedure, ensuring thatthe sealing ring, fuel pipe and hoseconnections are secure.17. Run the engine and recheck all connectionsto ensure no fuel leaks exist. Reverse theremaining removal procedure.FUEL FILTER6.7.8.9.10.Fit a new filter observing the direction of flowarrow on the canister.Tighten the single nut and bolt.Fit the inlet and outlet hoses. Tighten theunions to a torque of 20-25 ft lb(27-34Nm).Refit the fuel pump relay, reconnect thebattery. Recode the radio.Start the engine and inspect for fuel leaksaround the hose connections.Remove and refitWARNING: ENSURE THAT THE FUEL HANDLINGPRECAUTIONS GIVEN IN SECTION 01 -INTRODUCTION REGARDING FUEL HANDLINGARE STRICTLY ADHERED TO WHEN CARRYINGOUT THE FOLLOWING INSTRUCTIONS.WARNING: THE SPILLING OF FUEL ISUNAVOIDABLE DURING THIS OPERATION.ENSURE THAT ALL NECESSARY PRECAUTIONSARE TAKEN TO PREVENT FIRE AND EXPLOSION.Removing:. >,1. Depressurise the fuel system.2. The fuel filter is located on the right-handchassis side member forward of the fuel tankfiller neck. Access to the filter is gainedthrough the right-hand rear wheel arch.ADDITION: SEPT. 89 79


1191 FUEL INJECTION SYSTEM:FUEL FILLER FLAP RELEASE BUTTONFUEL FILLER FLAP RELEASE ACTUATORThe fuel filler flap is no longer part of the centrallocking system on 1991 model year vehicles. Thefiller flap is permanently locked. To release the flappress the button situated on the steering columnshroud. On closing, the filler flap will be lockedautomatically. Note that the release button will onlywork with ignition switched OFF.Remove and refitRemoving1. Disconnect the battery negative lead.2. Carefully pry the release button from thesteering column shroud.Remove and refitRemoving1. Ensure that the fuel filler flap is released.Disconnect the battery negative lead.2. Remove eight screws, and withdraw theclosure panel, situated in the right hand sideof the load space.3. Release two screws and maneuver the actuatorclear of its mounting.4. Disconnect the wiring plug.5. Withdraw the actuator.RR2031M3. Remove the release button from the shroudand disconnect the two wiring connectors.Ensure that the wires protrude through theshroud to facilitate reassembly.Refitting4. Reverse the removal procedure. Recode theradio.RR2932MRefitting6. Reverse the removal procedure. Recode theradio.,,:....’.‘.’..I ::‘, ,. ,;.’:..X‘.a0 ADDITION: SEPT. 89.:


ot;; 1987COOLINGSYSTEMCOOLANTDrain and refillDrainingWARNING: Do not remove the expansion tankfiller cap when the engine is hot because thecooling system is Pressurized and personalscalding could result.3. Disconnect the radiator bottom hose andallow the coolant to drain into a suitablecontainer. Use a clean container if the coolantsolution is to be reused. Reconnect thebottom hose after draining and tighten thehose clamp.1. Remove the expansion tank filler cap by firstturning it counter -clockwise a quarter of aturn to allow pressure to escape, then turn itfurther in the same direction and lift off.::..4. Remove the engine drain plugs, one each sideof the cylinder block, beneath the exhaustmanifolds. Allow the coolant to drain and refitthe plugs.2. Remove the radiator filler plug and washer toassist drainage.See the following coolant requirements beforerefilling the system.Continued4REVISED: jUNE 87


COOLINGSYSTEM1987 k”d;‘;riCoolantrequirementsRefillingFrost precautions and engine protection.The engine cooling system MUST ALWAYS be filledand topped-up with a solution of water andanti-freeze, winter and summer. NEVER use wateralone as this may corrode the aluminiun alloy.CAUTION: Do not use salt water otherwisecorrosion will occur. ln certain territories wherethe only available natural water supply has somesalt content use only rain or distilled water.RecommendedsolutionsAnti-freeze: Universal anti-freeze or permanenttype ethylene base, without methanol, containing asuitable inhibitor for aluminium engines and engineparts.5. Pour 4.5 litre (I gall) of water into the radiator.6. Add the recommended quantity of anti-freeze.7. Top-up the radiator with water, refit theradiator filler plug and washer and tighten.8. Add water to the expansion tank, up to the‘WATER LEVEL’ plate.NOTE: The water level plate on later models hasbeen deleted from the expansion tank, thereforethe coolant should be filled to the top of thesensor float which is approximately 1.00 inch (25mm) below the filler neck9. Fit the expansion tank filler cap.Use one part of anti-freeze to one part of water.Anti-freeze can remain in the cooling system andwill provide adequate protection for two yearsprovided that the specific gravity of the coolant ischecked before the onset of the second winter andtopped-up with new anti-freeze as required.Vehicles leaving the factory have the cooling systemfilled with 50% anti-freeze and 50% water mixture.This gives protection against frost down to minus36°C (minus 33°F). Vehicles so filled can beidentified by a label affixed to the radiator.NOTE: Should ambient temperatures be belowthat stated above refer to Anti-Freeze Data inRecommended Lubricants, Fluids and Capacitiesin Section OS. instructions in the chart must bestrictly adhered to before driving the vehicleaway.10.11.Run the engine until normal operatingtemperature is attained, that is, thermostatopen.Allow the engine to cool, then check the ---.,coolant level and top-up if necessary. 1After the second winter the system should bedrained and thoroughly flushed. Before adding newanti-freeze examine all joints and replace defectivehoses to make sure that the system is leakproof.See the ‘Recommended Lubricants Fluids andCapacities’, Section 09, for protection quantities.2 REVISED: jUNE 87,. :::


:COOLING SYSTEM I26 1EXPANSION TANK COOLANT LEVEL SENSORRemove and refitRemovingWARNING: Do not remove the expansion tankfiller cap when the engine is hot because thecooling system is pressurized and personalscalding could result.1.2.3.Remove the expansion tank filler cap by firstturning it counter -clockwise a quarter of aturn to allow pressure to escape, then turn itfurther in the same direction and lift off.Disconnect the hose to the radiator.Disconnect the multi-plug to the coolant levelsensor.4. Remove the pinch bolt.Remove and refitRemovingWARNING: Do not remove the expansion tankfiller cap when the engine is hot because thecooling system is pressurized and personalscalding could result.1. Disconnect the multi-plug from the sensor.2. Remove the expansion tank filler cap by firstturning it counter -clockwise a quarter of aturn to allow pressure to escape, then turn itfurther in the same direction and lift off.3. Release the retaining nut and withdraw thesensor from the expansion tank.., ”‘.’5. Lift out the expansion tank. Refitting. .“, ,.’..:Refitting 4.5.6. Reverse 1 to 5.7. Replenish the cooling system.8. Check for leaks around all hose connections.Reverse the removal instructions.Start engine and run until normal runningtemperature is attained, thermostat open,check for coolant leaks around the sensor.::;+’I_-::.. (,..‘. !3 .”,,:


FAN BELTCheck and adjust tension, 1 and 5 to 6Remove and refit, 1 to 6RemovingWARNING: Disconnect the battery negativeterminal to prevent the engine being startedbefore removing or adjusting drive belts.1. Loosen the idler pulley pivot bolt.2. Pivot the idler pulley inwards.3. Lift off the fan belt.VISCOUS COUPLING, FAN BLADES, PULLEY ANDFAN COWL ,.Viscous coupling-remove and refit 1 to 5Fan blades-remove and refit 1 to 5 and 6Fan cowl-remove and refit 1 to 4Fan pulley-remove and refit 1 to 7RemovingWARNING: Disconnect the battery negativeterminal to prevent the engine being startedbefore removing or adjusting drive belts.1. Loosen the nut securing the viscous couplingand fan blade assembly to the water pumpshaft.. ‘.NOTE: The nut securing the viscous unit tothe water pump has a left hand thread, torelease the nut, turn in a clockwisedirection when viewed from the front of theviscous unit.2. Remove the four fan cowl fixings and lift thecowl out of its lower mountings.RefittingI4.5.6.Locate the fan belt on the pulleys.Adjust the fan belt using the idler pulley togive 4 to 6 mm (0.19 to 0.25 in) freemovement when checked midway betweenthe fan and crankshaft pulleys by hand.Tighten the idler pulley pivot bolt and checkthe adjustment.NOTE: Re-check the belt adjustment afterapproximately 1500 km (1,000 miles)running when a new belt has been fitted.3. Remove the viscous coupling securing nut andwithdraw the assembly.4. Remove the fan cowl, if necessary.5. Remove the fan blades from the viscouscoupling. if necessary. 46. Remove the fan belt and, if fitted, thecompressor belt.7. Remove the pulley fixings and withdraw thepulley.:;.j;,;.,.‘.” . . . .4


PO;;; 1987COOLING SYSTEMRADIATORRemove and refitRemoving1.2.3.4.5.Drain the cooling system.Remove the fan blades.Remove the fan cowl.Disconnect the top hose from the radiator.Disconnect the hose to the expansion tank atthe radiator.Refitting8.9.Reverse the above procedure, ensuring the fanblades are fitted correctly. The fan is markedFRONT and should be fitted with the wordFRONT closest to the radiator. See Torquevalue+Section 06 for correct torque figure.Adjust the fan belt and compressor belt.,:6. Disconnect the hose to the thermostat elbowat the intake manifold.7. Remove the fixings trom each side of theradiator.8. Withdraw the radiator bt~ lifting from itslocatlons. Check the condition of the rubbermounting pads.Refitting9. Reverse I to 8 noting the assembly order ofthe radiator side fixings and ensuring that theradiator sealing strips are correctI\, located andsecure.10. Check lor coolant leaks around all hoseconnections.REVISED: JULY 88 5,


:THERMOSTATTesting. .Remove and refitTestRemoving1. Partially drain the cooling system, until coolantlevel is below thermostat housing.2. Disconnect the hose from the thermostathousing.3. Disconnect the electrical connections to thewater temperature switch.6. Note that the rating of the thermostat is 88°C(190°F). Place the thermostat in a suitablecontainer half full of water. Heat the water andobserve the temperature at which thethermostat opens. Should the thermostat openbetween 85°C (185°F) and 89°C (192°F) theunit is operating satisfactorily.Refitting .7.8.9.10.Insert the thermostat with the jiggle pin/venthole uppermost (12 o’clock position).Using a new joint washer, fit the outlet elbowand tighten to the correct torque, see Torquevalues-Section 06.Reverse 1 to 3.Check for coolant leaks around all hoseconnections and joint faces.4. Remove the outlet elbow.5. Withdraw the thermostat..,:..: . . . . .6REVISED: JULY 88:


,.:KAIYLJCROVER COOLING SYSTEMWATER PUMP RefittingRemove and refitRemoving8. Lightly grease a new joint washer and place itin position on the timing cover.WARNING: Disconnect the battery negativeterminal to prevent the engine being startedbefore removing or adjusting drive belts.1. Drain the engine cooling system.-2. Remove the fan belt, power steering pumpand compressor belt.3. Remove the fan blades and pulley.4. Disconnect the inlet hose from the waterpump.5. Release the alternator adjusting link and thepower Steering pump fixings.6. Remove the remaining water pump bolts.7. Remove the water pump and joint washer.9.10.11.12.13.14.15.16.17.18.Clean the threads of the four long bolts andcoat with Loctite 572 thread lubricant-sealant.Locate the water pump in position.Locate the alternator adjusting link andpower-steering pump bracket.Leave the alternator adjusting link loose andtighten the remaining water pump housingbolts evenly and to the correct torque, seeTorque values-Section 06.Connect the inlet hose to the water pump.Fit the fan pulley.Fit and adjust the fan belt, power steeringpump belt and compressor belt.Fit the fan blade assembly.Refill the cooling system.Check for coolant leaks around all hoseconnections and joint faces.


26 1 COOLING SYSTEMRnlYclCROVERCOOLING SYSTEM FAULT DIAGNOSIS5YMPTOM POSSIBLE CAUSE CURE. ..‘)h“.4. EXTERNAL LEAKAGE 1. Loose hose clamps 1. Tighten2. Defective rubber hose 2. Replace3. Damaged radiator seams 3. Rectify4. Excessive wear in the water 4. Replacepump5. Loose core plugs 5. Replace6. Damaged gaskets 6. Replace7. Leaks at the heater connections. 7. Rectify0. Leak at the water temperature 8. Tighten the transmittertransmitter?B - INTERNAL LEAKAGE 1. Defective cylinder head gasket2. Cracked cylinder wall3. Loose cylinder head1. Replace. Check engine oil forcontamination and refill if necessary2. Replace cylinder block3. Tighten. Check engine bolts for oilcontamination and refill as necessaryC - WATER LOSS 1. Boiling 1. Ascertain the cause of engineoverheating and correct as necessary2. Internal or external leakage 2. See items A and B3. Restricted radiator or inoperative 3. Flush radiator or replace the thermostatthermostatas necessary.D - POOR CIRCULATION 1. Restriction in system2. Insufficient coolant3. Inoperative water pump4. Loose fan belt5. Inoperative thermostat1. Check hoses for crimps, reverse-flush theradiator, and clear the system of rust andsludge2. Top-up coolant3. Replace4. Adjust5. Replace-‘\,:‘. 1.’.,8


IVWYUCROVERCOOLING SYSTEMiYMPTOM POSSIBLE CAUSE CUREi - CORROSION 1. Excessive impurity in the waler 1. Use only soft, clean water together withcorrect anti-freeze mixture.2. Infrequent flushingand draining 2. The cooling system should be drainedof systemand flushed thoroughly at least once ayear.3. Incorrect anti-freeze mixtures 3. Certain anti-freeze solutions have acorrosive effect on parts of the cooling.system. Only recommended solutionsshould be used.F - OVERHEATING 1. Poor circulation 1. See item D2. Dirty oil and sludge in engine. 2. Refill3. Radiator fins choked with chaff, 3. Use air pressure from the engine side ofmud etc.the radiator and clean out passagesthoroughly4. Incorrect ignition timing5. Insufficient coolant6. Low oil level7. Choked or damaged8. Dragging brakes9. Overloading vehicle10. Driving in heavy sand or mud11. Engine labouring on gradients12. Low gear work13. Excessive engine idling14. Inaccurate temperature gauge15. Defective thermostat4. Check using electronic equipment5. See item D6. Replenish7. Rectify or replace exhaust pipe or muffle8. Adjust brakes9. In the hands of the operator10. In the hands of the operatorIl. In the hands of the operator12. In the hands of the operator13. In the hands of the operator14. Check or replace15. Check or replaceG - OVERCOOLING 1. Defective thermostatI. Check or replace2. Inaccurate temperature gauge2. Check or replace9


.::,’ ”


X‘1:KANbtROVERCOOLING SYSTEMCOOLING SYSTEM - 1989 model year.‘,The 3.9 litre engine has a revised ‘partial flow’ typecooling system. A new radiator incorporates oilcoolers in both end tanks - left hand side,transmission oil cooler - right hand .ide, engine oilcooler.A supplementary transmission oil cooler is still fittedin front of the radiator and condenser fans.The transmission oil high temperature warning lightsensor is now fitted under the hood adjacent to theradiator end tank.COOLANTDrain and refillDrainingWARNING: Do not remove the expansion tankfiller cap when the engine is hot, because thecooling system is pressurised and personalscalding could result.3. Disconnect the bottom hose at its junctionwith the radiator and allow the coolant todrain into a suitable container. Ensure that thecontainer is clean if the coolant solution is tobe re-used. Reconnect the bottom hose afterdraining and re-tighten the hose clamp.1. Remove the expansion tank filler cap by firstturning it counter-clockwise a quarter of a turnto allow pressure to escape, turn it further inthe same direction and lift off.‘. “.’,4. Remove the engine drain plugs, one each sideof the cylinder block, beneath the exhaustmanifolds. Allow the coolant to drain, refit andtighten the plugs.2. Remove the radiator filler plug and ‘0’ ring toassist drainage.,’Continued.,::. .(,ADDITION: SEPT. 88 / REVISED: DEC 88 11(.


-l26 COOLING SYSTEM ROVERNAIYUL0.5.6.7.9.NOTE: It is not possible to drain all thecoolant retained in the heater system. Flushthrough the system, after draining, bypouring clean water into the fill tower, (seeRR2659E1, with the bottom hosedisconnected and engine drain plugsremoved.Pour the correct solution of water andanti-freeze into the expansion tank until theradiator is full.Start the engine and run it until normaloperating temperature is attained, topping upas necessary.Refit the radiator filler plug and ‘0’ ring, fittinga new ‘0’ ring if required. Tighten to thecorrect torque, see Torque Values, section 06.Fit the expansion tank filler cap.Allow the engine to cool, check coolant leveland top up the expansion tank until the levelreaches the level indicator on the inside of thetank.CAUTION: The following fill procedureMUST be followed if the heater pipesmounted on top of the rocker cover havebeen removed for any reason.RADIATOR/OIL COOLERSRemove and refitRemoving1.2.3.4.5.6.7.Drain the cooling system.Remove the fan blade assembly.Remove the fan cowl.Disconnect the radiator top hoses.Disconnect the four transmission and engineoil cooler connections to the radiator endtanks. Note that oil spillage will occur whenconnections are loosened. Blank off exposedoil connections.Disconnect the transmission oil temperaturesensor plug.Remove the radiator securing brackets fromeach side.8. Remove the radiator unit by lifting from itslocation. Check the condition of the rubbermounting pads.Refitting9. Check that the radiator sealing strips aresecurely located.RR2669E\ . 10. Transfer the oil cooler adaptors if fitting a newradiator.10. Remove the plug from the fill tower.11. Reverse the removal procedure, ensuring that11. Briskly pour the correct solution of water andoil cooler connections are tightened to theanti-freeze into the fill tower until the radiatoris full.specified torque values before fitting the fanblades and cowl.12. Start the engine and run it until normaloperating temperature is attained, topping up11. Clean any coolant/oil spillage from, the vehicle.12. Check all connections for coolant?oil leaks.as necessary.13. Refit the radiator filler and fill tower plugs,fitting new ‘0’ rings if required. Tighten to thecorrect torque, See Torque Values, section 06.14. Fit the expansion tank filler cap.15. Allow the engine to cool, check coolant levelin the expansion tank and top up until thelevel reaches the level indicater on the insideof the tank..’ I., !..i12 ADDITION: SEPT. 88 / REVISED: DEC 88


:.,.,KMl\UCROVER COOLING SYSTEMcRR2601EContinuedADDITION: SEPT. 88


1261 COOLING SYSTEMMIWULROVEREXPANSION TANKRemove and refitRemovingWARNING: Do not remove the expansion tankfiller cap when the engine is hot, because thecooling system is pressurised and personalscalding could result.I. Remove the expansion tank filler cap by firstturning it counter-clockwise a quarter of a turnto allow presure to escape, turn it further inthe same direction and lift off.2. Disconnect the radiator hose from the bottomof the expansion tank, allowing the coolant todrain into a suitable container.3. Disconnect the’ bleed hose to the top of theradiator.4. Disconnect the wiring to the coolant sensor.5. Remove the bolt from the securing strap.6. Lift out the expansion tank.Refitting7. Reverse removal instructions.8. Replenish the cooling system.9. Check for leaks around all hose connectionsADDITION: SEPT. 88


R”o”v’;l; 1990COOLING SYSTEMCOOLING SYSTEM - 1990 model yearThe cooling system is improved by the introductionof a larger, plastic expansion tank.COOLANTDrain and refillDraining,WARNING: Do not remove the expansion tankfiller cap when the engine is hot, because thecooling system is pressurised and personalscalding could result.NOTE: The expansion tank is fitted with ascrewed filler cap which incorporates a lowcoolant sensing unit.1. Remove the expansion tank filler cap by slowlyturning it anti-clockwise, pause to allowpressure to escape, continue turning it in thesame direction and lift off.Disconnect the bottom hose at its junctionwith the radiator and allow the coolant todrain into a suitable container. Ensure that thecontainer is clean if the coolant solution is tobe re-used. Reconnect the bottom hose afterdraining and re-tighten the hose clamp.2. Remove the radiator filler plug and ‘0’ ring toassist drainage.4. Remove the engine drain plugs, one each sideof the cylinder block, beneath the exhaustmanifolds. Allow the coolant to drain, refit andtighten the plugs‘.,r-‘., .,IADDITION: SEPT. 89 15:


.NOTE: It is not possible to drain all the coolantretained in the heater system. Flush through thesystem, after draining, by pouring clean waterinto the fill tower, tsee RR2659E), with thebottom hose disconnected and engine drainplugs removed.5.6.7.8.9.Pour the correct solution of water andanti-freeze into the expansion tank until theradiator is full.Start the engine and run it until normaloperating temperature is attained, topping upas necessary.Refit the radiator filler pfug and ‘0’ ring, fittinga new ‘0’ ring it required. Tighten to thecorrect torque, see Torque Values, section 06.Fit the expansion tank filler cap.Allow the engine to cool, check coolant leveland top up the expansion tank until the levelreaches the seam of the expansion tank.EXPANSIONTANKRemove and refitRemovingWARNING: Do not remove the expansion tankfiller cap when the engine is hot, because thecooling system is pressurised and personalscalding could result.Remove the expansion tank filler cap by firstturning it slowly anti-clockwise, pause to allowpressure to escape, continue turning it in thesame direction and lift off.Disconnect the two hoses from the bottom ofthe expansion tank, allowing the coolant todrain into a suitable container.Remove three fixing bolts and remove theexpansion tank from its mountings.:.’CAUTION: The following fill procedureMUST be followed if the heater pipesmounted on top of the rocker cover havebeen removed for any reason.,. .’ :RefittingRR2169E\ ’ -‘.4. Reverse removal instructions.5. Replenish the cooling system.6. Check for leaks around all hose connections.‘;:iI10. Remove the plug from the fill tower.11. Briskly pour the correct solution of water andanti-freeze into the fill tower until the radiatoris full.12. Start the engine and run it until normaloperating temperature is attained, topping upas necessav.13. Refit the radiator filler plug and fill tower plug,fitting nev: ‘0 rings if required. Tighten to thecorrect torque, Set Torque Values, section 06.14. Fit the expansion tank filler cap.15. Allow the engine to cool. check coolant levelin the expansion tank and top up until thelevel reaches the seam of tl~e expansion tank.:., _:: ..,1 6ADDITION: SEPT. 89


::. ., ..PO;;; 1987 MANIFOLD AND EXHAUST SYSTEM [30 1EXHAUST SYSTEM COMPLETE‘.JEXHAUST SYSTEM COMPLETE WARNING: To prevent personal injury occurringfrom a hot exh‘aust system, DO NOT attempt to1:’ y:.,: ,: . Y...,..... .:v. NOTE: Ensure that no exhaust leaks are evident disconnect any of the components until ample,..’: in either a new or an old exhaust system, as this time has elapsed to allow the exhaust system towill affect vehicle performance, and contravene cool.;,. :;:A:


MANIFOLD AND EXHAUST SYSTEM.‘&S,\ ..Remove and refitRemoving1. Raise the vehicle on a suitable hoist and applythe parking brake.2. Remove the four fixings securing the grassshield (if fitted) to the mounting bracket at thecentre catalyst.3. Withdraw the grass shield from the bracket.EXHAUST MANIFOLDRemove and refitLeft handRight handRemoving1. Disconnect the front exhaust pipe(s) from themanifold(s).2. Tap back the bolt locking tabs and remove theeight bolts, lock tabs and washers.3. Remove the manifold(s) and old gaskets.4. Disconnect the electrical plugs from theLambda sensors.5. Remove the nuts and disconnect the frontpipe(s) from the manifold(s) and remove thegaskets.6. Loosen the pinch bolt clamps securing thefront pipe to the intermediate pipe.7. Withdraw the front pipe(s) with catalysts.8. Remove three bolts securing the intermediatepipe to the centre catalyst and withdraw thedoughnut.9. Remove the U-bolt from the pipe mountingbracket.* 10. Withdraw the intermediate pipe.11. Remove the U-bolt securing the centre catalystto the main muffler.12. Withdraw the catalyst.13. Remove the U-bolt from the tail pipemounting bracket.14. Withdraw the tail pipe and rear muffler.RefittingNOTE: Apply Firegum Putty, Part No. 15608to all exhaust system joints with theexception of the exhaust flange to manifoldflange where new gaskets should be fitted.15. Reverse the removal instructions.Refitting4. Ensure that the mating surfaces of the cylinderhead and exhaust manifold are clean andsmooth.5. Coat the threads of each bolt with anti-seizecompound.6. Place the manifold and new gaskets in positionon the cylinder head and fit the securing bolts,new lockplates and plain washers. The plainwashers are fitted between the manifold andlockplates.7. Evenly tighten the manifold bolts to thecorrect torque, see torque values-section 06,and bend over the lockplate tabs. i8. Reconnect the front exhaust pipe, using newexhaust flange gaskets...INTAKE MANIFOLD *IThe removal and refit of the intake manifold isincorporated in the Fuel Injection System,Section 19.‘. . .2 REVISED: DEC. 87


;:MANIFOLD AND EXHAUST SYSTEMj:.,.. .,,.:RR2387E.,,EXHAUST SYSTEM COMPLETERemove and refitNOTE: Ensure that no exhaust leaks are evidentin either a new or old exhaust system, as thiswill affect vehicle performance, and contraveneFederal emission regulations.WARNING: To prevent personal injury occurringfrom a hot exhaust system, DO NOT attempt todisconnect any ot the components until ampletime has elapsed to allow the exhaust system tocool.RemovingTail pipe and rear muffler1.2.3.4.5.Raise the vehicle on a suitable hoist and applythe parking brake.Remove the three bolts s&uring the tail pipeassembly to the intermediate pipe assembly.Remove the bolt securing the rear mountingbracket. to the chassis.Maneuver the tail pipe over the rear axle andremove from the vehicle.Retain the doughnut from the intermediatepipe for reassembly.ContinuedADDITION: SEPT. 88 3,.,,


,. .’‘..’6. Detach the rubber from the tailpipe andhanger.intermediate pipe and centre muffler7. Remove the three bolts securing the righthand branch of the intermediate pipe to theright hand catalyst.8. Release the pinch bolt clamp securing the lefthand branch of the intermediate pipe to theleft hand catalyst and slide the clamp alongthe pipe.9. Remove the bolts securing the front and rearhanger brackets to the chassis.10. Detach the rubbers from the main mufflerassembly and hangers.11. Carefully separate the intermediate pipes fromthe front downpipes.12. Retain the doughnut from the right hand joint.Front downpipes13. Disconnect both Lambda sensor multiplugs.14. Remove the nuts and release the frontdownpipes from the manifolds, discard theRefittinggaskets.15. lf the original system is being refitted, examinethe system for damage and general conditionrenew sections as necessary.16. Clean any previous putty from the doughnutsand exhaust pipe joints.17. Fit NEW gaskets to the manifold joint face.NOTE: Apply exhaust sealer to all exhaust systemjoints with the exception of the exhaust flangeto manifold flange.18. Reverse the removal instructions.19. Examine a new or original system for leaks andensure that the system does not foul anyunderbody components. If exhaust leaks orinterference exists loosen the joints reseal andreset as necessary._‘.: ‘.4ADDITION: SEPT. 88..‘: .,


MANIFOLD AND EXHAUST SYSTEM 130 1RR277-mEXHAUST SYSTEM COMPLETE Remove and refit:. ..,’ ,: ‘.~..:.::!:.To improve sealing and accuracy of assembly, 1990model year vehicles have a new two piece exhaustsvstem.NOTE: Ensure that no exhaust leaks are evidentin either a new or old exhaust system, as thiswill affect vehicle performance.WARNING: To prevent personal injury occurringfrom a hot exhaust system, DO NOT attempt. .todisconnect any of the components until ampletime has elapsed to allow the exhaust system tocool.RemovingRaise the vehicle on a suit$ble ramp. apply theparking brake.Catalyst vehicles only: Disconnect the twolambda sensor wiring connectors.Remove the two bolts securing the rearexhaust assembly to the front exhaustassembly.Remove the nuts and release the frontdownpipes fromt the manifolds. Discard thegaskets.ADDITION: SEPT. 89 5


I301 MANIFOLD AND EXHAUST SYSTEM1990 ;;“d;l;;5. Lower the front exhaust assembly, retrievingthe doughnut from the joint.NOTE: The assistance of a second mechanicis required for removing and refitting therear exhaust assembly.6. Remove the bolts securing the three hangerbrackets to the chassis. Lower the exhaustassembly onto the rear axle. Detach therubbers from the hanging brackets.7. Place extended axle stands underneath thechassis, in front of the chassis mounted reartowing brackets.8. Lower the hoist until the vehicle weight issupported securely on the stands.9. Lower the hoist until the rear shock absorbersare almost fully extended.10. Move the rear exhaust to a diagonal positionwith the centre silencer to the right of thevehicle.11. Facing the rear of the vehicle, twist theassembly counter-clockwise until it clears therear axle.12. Remove the rear exhaust assembly from thevehicle.Refitting13. Position the rear exhaust assembly over therear axle in a diagonal position, as forremoving.14. Twist the assembly clockwise until it is in themounting position.15. Reverse the removing instructions 1. to 9.using new manifold gaskets and applyingexhaust sealer to the system joint.16. Examine the system for leaks and ensure thatthe system does not foul any underbodycomponents. Rectify as necessary.J6 ADDITION: SEPT. 89:.“.


R”;;; 1987LT230 TRANSFER GEARBOX [39 1‘.‘.LT230 TRANSFER BOXThe following operations can be carried out withthe gearbox in the vehicle. For ease of working, thevehicle should be raised on a suitable hoist orplaced over a pit.SPEEDOMETER DRIVE PINIONRemove and refitRemoving1. Disconnect the battery.2. Raise the vehicle on a suitable hoist.3. Remove the speedometer drive clamp and nutand withdraw the cable.4. Pry out the drive pinion assembly.Refitting5. Push in a new assembly and fit thespeedometer cable and secure with the clampand nut.REAR OUTPUT SHAFr OIL SEALService tool:18C1422-Mainshaft rear oil seal replacerRemove and refitRemovingRefitting9. Pre-grease between the seal lips. Insert thedouble lipped oil seal, open side inwards,using service tool 18Gl422 until contact ismade with the bearing circlip. Take care not totouch the seal lips while fitting.10. Fit the dust cover.11. Lubricate the surface of the flange which runsin the seal and carefully fit the flange.NOTE: To replace the flange bolts firstremove the circlip before fitting the flange.12. Secure the flange with the nut and washer andtighten to the specified torque (see section06-Torque values).13. Fit the back plate to the output housing usingthe 4 bolts and plain washers.NOTE: The two lower fixings also hold theoil catcher which before fitting is coatedwith a silicone rubber sealant on the matingface.14. Fit the brake drum and retain with the twoscrews.15. Reconnect the drive shaft and tighten to thespecified torque (see section OC-Torquevalues).1. Disconnect the battery.2. Raise the vehicle on a suitable hoist.3. Disconnect the rear drive shaft from theoutput flange and tie to one side of thechassis.4. Remove the brake drum retaining screws andwithdraw the drum.5. Remove the four back plate bolts that alsoretain the oil catcher and remove the brakeback plate and catcher.NOTE: An hexagonal type socket should beused for these bolts.,...’6. Remove the output shaft nut, steel washer, feltwasher and withdraw the flange.7. Using the slot provided, lever off the dustcover.8. Pry out the output shaft oil seal(s)...i,..I: ,,..‘,:: .::, :.:REVISED: JULY 88,: ::


LT230 TRANSFER GEARBOX. jFRONT OUTPUT SHAFT OIL SEALService tool:18C1422-mainshaft rear oil seal replacerRemove, refit and adjustRemoving1.2.3.4.5.6.Refitting7.8.9.10.Disconnect the batten/.Raise the vehicle on a suitable hoist.Disconnect the front drive shaft from theflange and tie to one side of the chassis.Remove the output shaft nut, steel washer, feltwasher and withdraw the flange.Remove the oil seal shield.Pry out the oil seal(s).Pre-grease between the seal lips. Insert thenew double lipped oil seal, open side inwards,using service tool 18G1422 untit contact ismade with the bearing circlip. Take care not totouch the seal lip while fitting.Lubricate the running surface of the flange andfit it together with the oil seal shield.Secure the flange with the nut and washer andtighten to the specified torque.Refit the drive shaft and tighten to thespecified torque (see section 06.Torquevalues).TRANSFER BOX NEUTRAL WARNING SWITCHNOTE: An hexagonal type socket should beused for these bolts.6. Disconnect the four wiring connections to theswitch.7. Loosen the lock nut using a suitable wrenchand unscrew the warning light switch.Refitting and adjusting8.9.10.11.12.NOTE: Adjust switch position ONLY withtransfer box neutral selected.Connect suitable test equipment as shown.Refit the switch and screw in until test lamp 1is extinguished.Screw in switch a further l/3 to l/2 turn.Lock switch in position using the locknut.Select ‘Low Range’ test lamp 1 shouldilluminate. Select ‘High Range’ test lamp 2should illuminate. Select neutral, both testlamps should extinguish.I- --- 1I - - - - IRemove and refitRemoving1.2.3.4.5.Disconnect the battery.Raise the vehicle on a suitable hoist.Disconnect the rear drive shaft from theoutput flange and tie to one side of thechassis.Remove the brake drum retaining screws andwithdraw the drum.Remove the four back plate bolts that alsoretain the oil catcher and remove the brakeback plate and catcher.13.14.15.16.If adjustment is satisfactory, remove the testequipment and reconnect wiring leadscorrectly and check operation of the audiblewarning unit.Fit the back plate to the output housing usingthe 4 bolts and plain washers.NOTE: The two lower fixings also hold theoil catcher which before. fitting is coatedwith a silicone rubber sealant on the matingface.Fit the brake drum and retain with the twoscrews.Reconnect the drive shaft and ti&hten to thespecified torque (see section 06-Torquevalues).‘..;.2 REVISED: JULY 88


,R”;$ 1987LT230 TRANSFER GEARBOX ki? 1LT230 TRANSFER GEARBOXService tool: 18G 1425 - Guide studs (3) Also,locally manufactured adaptor plate, see below.Remove and refitAdaptor plate for removing transfer gearboxThe transfer gearbox should be removed fromunderneath the vehicle, using a suitabletransmission jack. An adaptor pla:e for locating thetransfer gearbox onto the jack can be manufacturedlocally to the drawing RR2195E.WARNING: Where the use of a transmissionhoist is necessary, it is ABSOLUTELY ESSENTIALto follow the hoist manufacturer’s instructions toensure safe and effective use of the .equipment.ARC WELD2s’s6-35 95 370.35 09-32’ 30’,/Ii.L..>*.:MATERIAL: STEEL PLATE*= TO BE DRILLED TO FIT TRANSMISSION JACK BEING USEDRR2195EContinuedREVISED: JULY 88 3 .”‘,,:/


. ...: : 1987 k”d;;iRemoving 11.1.2.3.4.5.6.7..,8.,:. 9.. .‘(. :’‘::iInstall the vehicle on a suitable hoist.Open the hood.Disconnect the battery.Release the airflow meter to plenum chamberhose.Remove the four screws securing the glovebox liner to the glove box and lift out theliner.Carefully pry the window lift switch panel awayfrom the front of the glove box.Identify each switch connection forre-assembly, disconnect the plugs and removethe switch panel.Remove the main and transfer gearbox knobs.Carefully pry the centre panel out of the floormounted console and remove it from thevehicle.12.13.14.15.16.17.Release the parking brake and remove thecotter pin, clevis pin and washer securing theparking brake cable to the parking brake lever.Carefully maneuver the assembly away fromthe radio housing and remove it from thevehicle.Release the large nut retaining the parkingbrake outer cable to the top of the gearboxtunnel.Remove the nut and feed the cable throughthe hole to the underside of the vehicle.NOTE: The illustration for the followingremoval instructions is located at the top ofthe following page.Raise the vehicle on the hoist and drain thetransfer gearbox.Release the nut and clamp securing thespeedometer cable to the rear of the transferbox.Withdraw the cable from the speedometerdrive pinion.10. Release the two bolts and two screws securingthe console assembly to the gearbox tunnel.RRleelE 15'1819.Release the four nuts securing the rear driveshaft to the rear output flange and tie to oneside of the chassis.Remove the four nuts securing the front driveshaft to the front output flange and tie to oneside of the chassis.:.J4 REVISED: JULY 88


LT230 TRANSFER GEARBOX27 3718--L------ tnr”77 k- -126 1920.21.22.23.24.25.26.Release the bolts securing the intermediateexhaust pipe to the centre catalyst andseparate the pipes. Retrieve the dougnut.Remove the clamp at the tailpipe bracket,carefully tie the exhaust to the chassis sidemember.Manufacture an adaptor plate in accordancewith the drawing, to attach to the transmissionjack and transfer box to facilitate removaltRR2195E).Place four, 30mm (1.250 in) long spacersbetween the top of the hoist and the adaptorplate at the securing points and secure theadaptor plate to the hoist.Remove the four central bolts from thetransfer box bottom cover, move the jack intoposition and secure the adaptor plate to thetransfer box.Adjust the jack to take the weight of thetransfer box.Remove the tie bar from the transfer gearbox.27.28.29.30.31.32.33.34.35.Remove the right-hand side mounting bracketto chassis nuts and bolts.Remove the rear left-hand side mountingbracket to chassis nuts and bolts.Remove right-hand side mounting bracket toflexible mounting rubber retaining nut andplace bracket aside.Lower the jack until the rear brake drum clearsthe rear passenger footwell.Remove the cotter pin and washers securingthe differential lock lever to the connectingrod, and disconnect the lever from the rod.Disconnect the electrical leads from thedifferential lock switch and neutral warningswitch.Remove the breather pipe from the top of thetransfer gearbox.Select low range transfer box gear position.’Release the high/low rod lower lock nut andremove the rod from the yoke.ContinuedJREVISED: JULY 88 5 :,’


; ,(’LT230 TRANSFER GEARBOX36. Place a suitable wooden block between themain gearbox and chassis cross-member, thenlower the jack until the gearbox contacts thewooden block.37. Remove the upper and lower bolts securingthe transfer box to the main gearbox.38. Fit three guide studs to the main gearbox 18C1425 and maneuver the transfer gearboxrearwards to detach it from the main gearbox.Refitting39. Make sure that the joint faces of the transferbox and main gearbox extension case areclean and that the three guide studs, 18C1425, are fitted to the extension case.40. Lubricate the oil seal in the joint face oftransfer box, secure the transfer box to theadaptor plate on the lifting hoist and raise thehoist until the transfer box can be locatedover the guide studs.41. Remove the guide studs and secure thetransfer box to the main gearbox extensioncase. Tighten the nuts and bolts to the correcttorque (see section 06-Torque values).42. Complete the refitting procedure by reversingthe removal sequence, noting the followingimportant points.43. After removing the lifting hoist and adaptorplate from the transfer box, clean the threadsof the four bolts for the transfer box bottomcover, coat them with Loctite 290 and fit themtogether with spring washers. Tighten to thespecified torque.44. Refill the transfer box with the correct gradeoil to the oil level plug hole. (See Section 09).45. Check, and if necessary top-up the oil level inthe main gearbox. Use the correct grade oil.(see section 09).46. Check the operation of the parking brake andadjust as necessary. (see section 10).1987 wxNbcROVER6 REVISED: JULY 88.‘. ,:.: ,


RANGEROVER LT230 TRANSFER GEARBOX r37- l7


- -..I 37 I LT230 TRANSFER GEARBOXIXMIYUCROVER. ..C ,.‘.2’‘I.’ -\ Li :?8


1. Transfer box. Case assembly.2. Power take-off assembly.3. tntermediate gear assembly and bottom cover.I1\CD


LT230 TRANSFER GEARBOXWMIYUCROVERLT230 TRANSFER GEARBOX OVERHAUL 18G 1423Service Tools:18G 47-7 -input gear cluster bearing conesremover/replacer18G 4788-l -Adaptor centre differential bearingremover18C 47BB-3 -Adaptor centre differential bearingremover button18C 257 Kirclip pliers18G 1205 -Drive flange wrench18G 1271 -Oil seal remover18G 1422 -Mainshaft rear oil seal replacer18G 1424MS 47MS 550LST 47-1LST 104LST 105LST 550-4-Adaptor/socket centre differentiallocknut remover/replacer-Centre differential bearingreplacer-Hand press-Bearing and oil seal replacerhandle-Adaptor centre differential bearingremover-Intermediate gear dummy shaft-Input gear mandrel-Intermediate gear bearing racesreplacerTRANSFER BOX DATAFront and rear bevel gear pre-load .............................High range gear end-float ..........................................Front differential bearing pre-load ..............................Input Rear bearing pre-load .......................................lniermediate shaft bearing pre-load . . . . . . . . . . . . . . . . . . .Parking brake removalSee text0.05 to 0.15 mm (0.002 to 0.006 in)0.56 to 1.69 Nm (S-15 in lb)0.56 to 2.25 Nm (S-20 in lb)0.56 to 1.69 Nm (S-15 in lb)Bottom cover removal1.2.Remove two countersunk screws and withdrawbrake drum.Remove four bolts securing the brakeback-plate; the two bottom fixings retain theoil catcher.3. Remove the six bolts and washers retainingthe bottom cover.4. Remove the bottom cover and gasket, discardthe gasket.NOTE: An hexagonal type socket should beused for these bolts.ST1570M10 REVISED: DEC. 87


KANbtROVER LT230 TRANSFER GEARBOX I37 1intermediate shaft and gear cluster removal1’ .5.“.Release stake nut from recess in intermediateshaft, remove stake nut and discard.Unscrew the single bolt and removeanti-rotation plate at the rear face of thetransfer box.ST‘610. Remove the taper roller bearings and bearing.spacer from the intermediate gear clusterassembly.ST157lM \ /7. Tap the intermediate gear shaft from thetransfer box.Power take-off cover removal8. Lift out the intermediate gear cluster anabearing assembly.9. Remove the ‘0’ rings from the intermediategear shaft and from inside the transfer box anddiscard.11. Remove five bolts and washers retaining thetake-off cover12. Remove the cover and gasket, discard thegasket.Continued


KANbtROVERinput gear removal13.14.15.16.Remove the two countersunk screws anddetach the main shaft bearing housing.Remove the gasket and discard.Withdraw the input gear assembly.Pry out and discard the oil seal at the front ofthe transfer box casing using service tool 18C1271.17. Drive out the input gear front bearing track.Frontoutput housing removal20. Remove the eight bolts and washers anddetach the output housing from the transferbox casing, taking care not to mislay thedowel. Remove the gasket and discard.,. :High/low cross-shaft housing removal18.‘,, ,’ 19.Remove the six bolts and washers retainingthe cross-shaft housing, ground lead andretaining clip.Remove the cross-shaft housing and gasket,discard the gasket.Centre differential removal21. Remove high/low selector shaft detent plug,spring and retrieve the ball with a suitablemagnet._I__,.” &‘&-“’h ,,/’ .2,1 p,..--a‘.n: ,..c’_' j:.." ; . I1 2


I:KANbtROVERLT230 TRANSFER GEARBOX22. Withdraw the centre differential and selectorshaft/fork assembly.Transfer case overhaul - dismantling25. Inspect the studs and dowels for wear ordamage. Remove if replacements are required.26. Remove the magnetic drain plug, copperwasher and filler/level plug. Discard thewasher.Rear output housing removalST1581Mi23. Remove six bolts and washers and detach therear output housing and shaft assembly fromthe transfer casing.24. Remove the gasket and discard.27. Drive out differential rear bearing track.28. Clean all areas of the transfer casing ensuringall traces of ‘Loctite’ are removed from facesand threads.ST1582MContinuedJI..A. . .:::. -.’x‘. ..,REVISED: DEC. 87 13


l-l 37 LT230 TRANSFER GEARBOXKANLtROVERTransfer case overhaul - re-assembling29.If previously removed, fit studs and dowels tofront face of the transfer casing. Use newcomponents where necessary.NOTE: The position of the radial dowelblade is set in line with the circle which isformed by the front output housing fixingholes.30.Refit magnetic drain plug with new copperwasher and tighten to the specified torque,loosely fit the filler/level plug.ST1583b.43. Remove speedo-drive housing. This can beeased out with a screwdriver.,;. :’ST1639MRear output housing overhaul-dismantling1. Using flange wrench 18G1205 and socketwrench remove the flange nut, steel and feltwashers, Ensure flange bolts are fully engagedin the wrench.2. Remove output flange with circlip attached. Ifnecessary, use a two-legged puller.NOTE: The circlip need only be released ifthe flange bolts are to be replaced.4.5.Remove housing from the vice and drive outthe output shaft, by striking the flange end ofthe shaft.Carefully pry off the oil catch ring using ascrewdriver in the slot provided.,:.14REVISED: DEC. 87:.a


KnlYutROVERLT230 TRANSFER GEARBOX6. Pry out and discard the seal from the outputhousing using tool 18G1271.9fgi!-10eJ:.10 +rjj7. Using circlip pliers 18G257, remove the circlipretaining the bearing.8. Drive out the bearing from the rear of thehousing.11. Slide off spacer and speedometer drive gearfrom output shaft.12. Clean all parts, replace the ‘0’ ring, oil seals,felt seal and flange nut. Examine all other partsfor wear or damage and replace, if necessary.ST1588MRe-assemblingST1586M9. Remove speedometer gear (driven) from itshousing.10. Remove the ‘0’ ring and oil seal and discard.13. Press output bearing into the housing. Do notuse excessive force. To facilitate fitting thebearing, heat the output housing case. This isnot to exceed 100°C (212°F).14. Retain bearing with circlip, using circlip pliers18G257.Continued15


l-l 37 LT230 TRANSFER GEARBOXKANCItROVER15. Pre-grease between the seal lips and fit newseal (open side inwards) using tool 18G1422.The seal should just make contact with thebearing circlip.ST1590MST1588k116. Carefully coat the lips of the seal with clean17.16.19.grease and refit oil catch ring onto outputhousing.Fit the ‘0’ ring and oil seal (open sideinwards) to speedometer housing.Lubricate the ‘0’ ring and seal with oil.Locate speedometer gear (driven) in housingand press into position.20.21.22.Slide drive gear and spacer on to the outputshaft.Locate output shaft into the bearing in thehousing and drive into position.Locate speedometer gear (driven) housingassembly into the output housing and press inuntil flush with the housing face.ST1540MJ.,::.’‘.. 16.,” ;:.’ : ., ::.


PO;;; 1987LT230 TRANSFER GEARBOX.’Centre differential unit overhaul -dismantling1.2.3.Secure centre differential unit to a vice fittedwith soft jaws, and release stake nut fromrecess.Remove stake nut using tool 18G1423 andsuitable socket wrench and discard stake nut.Remove the differential unit from the vice.5.6.7.Remove the high range gear and bush, takingcare not to disturb the high/low sleeve.Mark-the relationship of the high/low sleeve tothe hub and then remove the sleeve.Using a suitable press behind the low rangegear carefully remove the high/low hub andlow range gear.18G 1423. .ST1591M4. Secure hand press MS47 in vice with collars18C47BB-1 and using button 18C47BB13remove the rear taper bearing and collars.7ST1593MContinuedST1592MREVISED: APR. 88 17 ‘,,:


LT230 TRANSFER GEARBOX1987 KANGtROVER8. Substituting collar LST47-1 remove front taperroller bearing.9. Remove hand press from the vice.IO. Using soft jaws secure the differential unit inthe vice by gripping the hub splines.23211.12.13.14.1s.Remove the eight retaining bolts and lift offthe front part of the differential unit.Release the retaining ring and remove frontupper bevel gear and thrust washer.Remove the pinion gears and dished washersalong with the cross shafts.Remove the rear lower bevel gear and thrustwasher from the rear part of the differentialunit.Remove the rear differential unit from the viceand clean all components.ST1591 ,16. Inspect all components for damage or wear, fitnew components if necessary.17. Using soft jaws secure the rear (longest half)of the differential unit in the vice by grippingthe hub splines.18. Lubricate and install the cross shafts andpinion gears with new dished washers. DONOT fit the rear bevel gear at this stage.18 REVISED: APR. 88


LT230 TRANSFER GEARBOX22.Lubricate and fit the front bevel gear andthinnest thrust washer (FRC6956 1.05 mm).Fit front half of the differential casing ensuringthat the two engraved arrows are aligned.Fit securing bolts and tighten to the correcttorque (see section 06 - Torque values).Lubricate and insert the rear output shaft intothe bevel gear and check that the gears arefree to rotate.NOTE: Gears that have been run will rotatesmoothly and will require a torque of 0.56 Nm (5in lb). Equivalent force using spring balance: 0.45kg (1 lb).New gears will rotate with a notchy feel and willrequire a torque of not more than 2.26 Nm (20in lb). Equivalent force using spring balance: 1.72kg (3.8 lb).Keep all components well lubricated whencarrying out these adjustments.242024.25.26.27.28.29.Change the thrust washer for a thicker one ifthe torque reading is too low. Five thrustwashers are available in 0.10 mm steps rangingfrom 1.05 mm to 1.45 mm.Dismantle the unit when the front bevel gearthrust washer is selected.Remove and retain the front bevel and thrustwasher combination.Reassemble the unit with the rear bevel gearand thinnest thrust washer in position.Using soft jaws secure the front (shortest half)of the differential unit in the vice by grippingthe hub splines.Repeat the above procedure to obtain thecorrect thrust washer for the rear bevel gear.I23. Fit the parkbrake drum to the output driveflange and check the torque required to rotatethe gears. Tie a length of string around thebrake drum, attach a spring balance to thestring and carefully tension the string until aload to turn is obtained. Alternatively use atorque wrench applied to the brake drumflange nut. Rotate the drum slowly by hand toovercome initial load when using eithermethod. Note that illustration RR2332E showschecking torque at rear bevel gear.AR2332EContinued4REVISED: APR. 88 19


l-l 37 LT230 TRANSFER GEARBOX1987 K”d;;;Re-assembling30. Fit the selected thrust washer and bevel gearinto the rear differential unit.37. Invert the differential unit and secure in thevice.NOTE: During the following sequences allparts should be lubricated as they arefitted.-3418G 1424‘.,.‘.’31.32.33.34.35.36.Assemble both pinion assemblies and dishedwashers on to their respective shafts and fitthe rear differential unit. Secure the assemblieswith the retaining ring.Lubricate all the components.Fit the selected thrust washer and bevel gearinto the front upper differential unit.Align both units as previously described andsecure with the eight bolts to the specifiedtorque (see Section 06 - Torque values).Check the overall torque required to turn thedifferential. This should be approximatelyequal to the resistance of both bevel gearsadded together.Locate the front differential bearing onto thefront, upper differential shaft and press intoposition using larger end of tool 18C1424 asshown.38.39.40.41.Fit the low range gear, with its dog teeth awayfrom the differential assembly.Press the high/low hub on to the differentialsplines.Slide the high/low selector sleeve on to thehigh/low hub ensuring that the alignmentmarks are opposite each other.Fit the bush into the high range gear so thatthe flange is fitted on the opposite side of thegear to the dog teeth. Slide the bushed gearon to the differential assembly with the dogteeth down.. . . . .\.. . ...‘7,.2 0 REVISED: APR. 88.:


po;$ 1987LT230 TRANSFER GEARBOXNOTE: If the clearances vary from thosespecified in the data, at the beginning ofthe overhaul: the assembly must be rebuiltusing the relevant new parts.45.Peen the stake nut collar by carefully formingthe collar of the nut into the slot as illustrated.CAUTION: A round nose tool must be used forthis operation to avoid splitting the collar of thenut.I’42.43.44.Locate the rear differential bearing on to thehub and press it into position using thesmaller end of tool 18G1424.Fit the stake nut and tighten to the specifiedtorque using tool 18G1423 (see section06-Torque values).Check the end float of the high and low rangegears 0.05 to 0.15 mm (0.002 to 0.006 in).ST1604M ,++-A46. Clean and check high/low selector forkassembly for wear and replace if necessary.Continued1603M. .21:. ‘.


::, LT230 TRANSFER GEARBOX,’‘


R”;;; 1987LT230 TRANSFER GEARBOXCentre differential unit refitFront output housing overhaul -dismantlingI. Fit the selector fork/shaft assembly to thehigh/low selector sleeve on the differentialassembly, with detent groove to the rear ofthe differential assembly.2. Locate the differential assembly complete withselector fork into the transfer box casing. Itmay be necessary to rotate the output shaft toease fitment, and guide selector shaft into itshole.I. Unscrew seven retaining bolts and washersand remove the differential lock selector sidecover and gasket, discard the gasket.2. Unscr,ew three retaining bolts and washers andlift the differential lock finger housing andactuator assembly from the front outputhousing.3. Loosen the locknut and unscrew thedifferential lock warning light switch.4. Remove selector shaft detent plug. spring andball using a suitable magnet.5. Compress the selector fork spring and removethe two spring retaining clips.3. Fit selector shaft ball and spring through theside of the transfer box casing.4. Apply Loctite 290 to detent plug; fit andlocate, by screwing gently fully home and thenunscrewing two turns.Continued.,‘,.:. . ...’I: 1‘. .,


I...,.._’ .I 37 -1 LT230 TRANSFER GEARBOX 1987 ;;^d;;;6.7.8.Withdraw the selector shaft from the rear ofthe output housing.Remove the selector fork and spring throughthe side cover aperture.Remove lock-up sleeve from the rear of theoutput housing.STlGlOM13. Pry out and discard oil seal from outputhousing using service tool 1861271.14. Remove circlip with circlip pliers 18G257.9.Using flange wrench 18G1205 and socketwrench, remove the flange nut, steel and feltwashers.NOTE: Ensure that flange bolts are fullyengaged in the wrench.10. Remove the output flange with oil seal shield.NOTE: These parts need not be separatedunless the flange bolts are to be replaced.11.12.Drive output shaft rearwards from housingusing a soft headed mallet.Slide off the collar from the output shaft.15. Invert housing and drive out bearing frominside the case as shown.,_..’_.’24


o;Eg 1987LT230 TRANSFER GEARBOX b 116.,’..”.I’ 17.18.19.Drive out centre differential front taper rollerbearing track and shim.Drive out selector shaft cup plug fromhousing.Clean all components ensuring all traces of‘Loctitel are removed from faces and threads.Examine components for wear or damage andreplace if necessary.NOTE: Replace oil seal, felt seal and flangenut..:,. . .,.ST1614~Adjusting front differential bearing pre-load26. Measure original differential front bearing trackshim.27. Refit original shim into the output housing.28. Drift differential front bearing track into thehousing using a soft driver.Re-assembling‘.I.‘..20.21.22.23.24.25.Press the bearing into the housing; do not useexcessive force. To facilitate fitting thebeating, heat the front output housing. This isnot to exceed 100°C (212°F).Using circlip pliers 18G257, fit the bearingretaining clips.Pre-grease and fit a new oil seal (open sideinwards) using replacer tool 1861422, until theseal just makes contact with the circlip.Carefully coat the lips of the seal with cleangrease.Slide collar on to the output shaft, with itschamfered edge away from the dog teeth.Fit the output shaft through the bearing anddrive home.,ST1615M29. Grease and fit new gasket and locate the frontoutput housing on the transfer box casing.Continuedi‘. .’.,: ,:‘,,::.:-...;REVISED: DEC. 88 25‘,’


.’LT230 TRANSFER GEARBOX“.,...C,c’::.‘.’:


PO;;; 1987 LT230 TRANSFER GEARBOX [j7 141. Repeat the above operation for the rear, output flange.46. Compress the spring between the fork lugsand slide the retaining caps on to the shaftensuring the spring is seated in the ‘cupped’side of the caps.47. Apply a suitable sealant, a new seal cup, anddrive the cup into position.ST1644MST1643M,T-.42.43.44.4.5.Compress the selector shaft spring and fit tothe selector fork.Locate selector fork through front outputhousing side cover aperture, ensuring that thefork engages in the groove of the lock-upsleeve.Fit selector shaft through the aperture in thefront of the output housing and pass itthrough the selector fork lugs and spring intothe rear part of the housing.Rotate the selector shaft until the two flats forthe spring retaining caps are at right angles tothe side cover plate face.48.49.Fit selector shaft detent ball and spring in thetapped hole on top of the output housing.Apply Loctite 290 to detent plug threads.Screw detent plug gently home and thenunscrew two turns.49---@48,_:.: ,.: :ST161ContinuedREVISED: APR. 88 27 ”


..I LT230 TRANSFER GEARBOX‘.‘.Differential lock finger housingoverhaul-dismantling1.2.3.4.Unscrew and discard the ‘Nyloc’ nut andremove the operating lever and washer.Remove the pivot shalt from differential lockfinger housing.Remove the ‘0’ rings from the pivot shaft andhousing and discard.Clean all components; examine for wear ordamage and replace if necessary.9.10.Fit the differential lock finger housing into itsseating on the front output housing, ensuringthat the selector finger is located in the flat ofthe selector shaft.Apply Loctite 290 to the bolt threads andretain the lock finger housing with the threebolts and washers to the specified torque (seesection 06-Torque values).” ‘.Re-assembling5.6.7.8.Fit new ‘0’ rings on to pivot shaft and lockfinger housing and lubricate with oil.Locate the pivot shaft in the housing.Fit the differential lock lever over the pivotshaft so that the lever will point forward asshown. This lever is then in the correctoperating position.Retain the lever with a plain washer and new‘Nyloc’ nut.High/low cross-shaft housing overhaul1. Release the locknut and remove the neutralwarning switch.2. Remove the selector finger set screw andwithdraw the cross-shaft from the cross-shafthousing and remove the selector finger.Remove the ‘0’ ring from the cross-shaft.Drive out selector housing cup plug if7.8.necessary.Clean all the components and check fordamage or wear, replace if necessary.Apply sealant to a new cup plug and fit so thatthe cup is just below the chamfer for thecross-shaft bore.Fit new ‘0’ ring to cross-shaft.Lubricate the shaft and insert into thecross-shaft housing.Sll618MjREVISED: APR. 88


R”o”v’;l: 1987 LT230 TRANSFER GEARBOX (37 I. :9. Fit selector finger ensuring that it aligns withthe recess in the cross-shaft.Input gear overhaul-dismantlingClean the input gear assembly and examine forwear or damage. Remove the bearings only ifthey are to be replaced.Secure hand press MS47 in the vice and usingcollars 18G47-7 and button 18G47BB3, removerear taper roller bearing from input gearassembly.Invert input gear assembly in hand press andremove front taper roller bearing.Clean input gear..-,10.11.12.Apply Loctite 290 to the set screw and securethe selector finger to the cross-shaft and fullytighten to the specified torque (see sectionOC-Torque values).Grease and fit the high/low selector housinggasket on the front output housing.Fit high/low cross-shaft housing, ensuring thatthe selector finger locates in the slot of theselector shaft, and secure with six bolts andwashers to the specified torque (see section06-Torque values).Continued: ‘., ., :;:.:.,..a.REVISED: JUNE 87 29


LT230 TRANSFER GEARBOX1987 KANbtROVERRe-assembling5. Position rear taper roller bearing on input gearand using hand press MS47 and collars18647-7 press the bearing fully home.6. Invert input gear and fit the front taper rollerbearing using the press and collars.9. Reposition transfer box casing so the frontface is uppermost and fit oil seal (open sideinwards) using replacer tool 18G1422.J IMS 47; 47-71 3ST1622M )I7. Prop up the transfer box casing on the benchwith the rear face uppermost.8. Drive in the front taper bearing track.10. Lubricate both bearings with clean oil.11. Fit the input gear assembly into the transferbox casing with the dog teeth uppermost.30REVISED: IUNE 87


.’yo;;; 1987LT230 TRANSFER GEARBOX I37 1,...Checking input gear bearing pre-load 19.12. Secure bearing support plate in the vice. Drive13.14.15.16.17.18.out input gear bearing track, and remove shim.Clean bearing support plate and shim.Measure original shim and note its thickness.Fit the original shim to the support plate.Locate the bearing track in the support plateand press fully home.Apply grease to the gasket and fit on to thetransfer box casing.Fit the bearing support plate on to the transferbox casing and secure with the six bolts, butdo not tighten.Fit the service tool LSTl05 to input gear andengage the spline.20.21.22.23.24.25.262728.Tie a length of string to the cotter pin and fitit to the service tool as shown.Carefully tension the string using a springbalance, little or no resistance will be felt atthis stage. Tighten the bolts a little at a time,occasionally checking the rolling resistance.With the bolts tightened to the specifiedtorque the rolling resistance should be 2.26 kgto 9 kg (5 to 20 lb). NOTE: Alternatively usinga suitable torque wrench applied to the nut onthe service tool, a reading for a torque to turnshould be 0.56 to 2.25Nm (5 to 20 in lb).If the reading obtained is outside the abovelimits, the original shim must be changed.Remove the spring balance, string and servicetool.Remove the six bolts and the bearing supportplate.Drive out the input gear bearing track fromthe support plate and discard original shim.Select the correct size shim to obtain a loadto turn of 0.56-2.25Nm (5 to 20 in lb).Fit shim to support plate, locate bearing trackand press home.Fit bearing support plate and secure to transferbox casing with the six bolts but do nottighten.Repeat the rolling resistance check aspreviously described, and note the valueobtained.ContinuedJREVISED: DEC. 88 31:,


I371 LT230TRANSFER GEARBOXIntermediate gear assembly overhaul1. Drive out intermediate gear bearing tracks.2. Remove circiips.6. Fit the ‘0’ rings to the intermediate shaft andinto the intermediate shaft bore at the front ofthe transfer box casing.‘,,’sTl62SM3. Clean all intermediate gear components andlock plate. Check for damage or wear andreplace as necessary.4. Fit new circlips into the intermediate gearcluster.5. Using tools LST550-4 and MS550 fit bearingtracks into the intermediate gear cluster.Intermediate gear re-assembly7. Check for damage to the intermediate shaftthread and if necessary clean up with a finefile or stone.8. Lubricate the taper roller bearings andintermediate gear shaft.9. Insert new bearing spacer to gear assembly,followed by the taper roller bearings.: ,MS550ST1 649M10. Fit dummy shaft LST104 into the intermediategear cluster.I 1. Locate the gear assembly into the transfer boxcasing from the bottom cover aperture.ST1630MREVISED: DEC. 88


FOE; 1987LT230 TRANSFER GEARBOX (37112. Insert intermediate shaft from the front of thetransfer box casing, pushing the dummy shaftright through as shown and remove. (Makingsure that the intermediate gear cluster mesheswith the input gear and higher range and lowrange gears).Adjusting intermediate gear torque-to-turn16.17.18.19.20.Select neutral.Fit service tool LSTIOS to input gear andengage spline.Tie a length of string to a cotter pin and fit tothe service tool as shown. Attach the springbalance to the string.To obtain the correct figures and to collapsethe spacer within the intermediate gear cluster,tighten the intermediate shaft nut until theload-to-turn has increased by 3.7 kg (7 lb) +1.63 kg (f 3 lb) on that noted when checkinginput shaft load-to-turn.Peen the stake nut by carefully forming thecollar of the nut into the intermediate shaftrecess, as illustrated.CAUTION: A round nose tool must be used forthis operation to avoid splitting the collar of thenut.13. Turn the intermediate shaft to allow fitting ofretaining plate.14. Fit retaining plate and secure with retainingbolt and washer.15. Fit the intermediate gear shaft retaining stakenut. Do not tighten at this stage.ContinuedREVISED: DEC. 8733,:.:.,


.,ILT230 TRANSFER GEARBOXPower take-off cover-reassembleDifferential lock switch adjustment.’21. Clean power take-off cover and gasket face.22. Fit the two countersunk screws and tighten tothe specified torque (see section 06-Torquevalues).23. Remove the six bolts from the bearing supportplate.24. Apply sealant to the cover plate gasket and fitit to the bearing support plate.25. Apply Lodite 290 to bolt threads and securethe power take-off cover with the six boltsand washers to the specified torque (seesection 06-Torque values).1. Select differential locked position by movingthe differential lock lever towards the rightside of the transfer box casing.2. Apply sealant to the differential lock warninglight switch and fit to the top of the frontoutputhousing.3. Connect a test lamp circuit to the differentiallock switch.4. Screw in the lock switch until the bulb isilluminated.5. Turn in the switch another half a turn andtighten with the locknut against the housing.Bottomcover-reassemble26. Clean bottom cover and gasket face.27. Apply sealant to cover gasket and fit totransfer box casing.28. Apply Loctite 290 to bolt threads and securethe bottom cover with six bolts and washersto the specified torque (see section 06-Torquevalues).3-I+ -I:.:ST1 634M-.,:: :6. Disconnect the battery and move thedifferential lock lever to the left to disengagedifferential lock.7. Clean the front output housing side cover.8. Grease and fit side cover gasket.9. Apply Loctite 290 to bolt thread& fit sidecover and secure with seven bolts and washersto the specified torque (see se&n 06-Torquevalues).REVISED: DEC. 87


R”$;f; 198711230 TRANSFER GEARBOXNeutral warning switch adjustment Parking brake drum-reassemble‘.1. Connect suitable test equipment as shown.2. Fit the switch and neutral warning switchlocknut ensun, ,g correct setting for switch.3. To attain the correct setting the followingprocedure is applied:4. Screw the switch in until test lamp I isextinguished.5. Screw in switch a further 1/3 to l/2 turn.6. Lock switch in position using locknut.7. Select ‘Low Range’ test lamp 1 shouldilluminate. Select ‘High Range’ test lamp 2should illumrnate. Select neutral both testlamps should extinguish.1. Clean brake backplate and oil catcher andapply sealant to the catcher joint face.2. Locate brake backplate on the rear outputhousing with the brake operating lever on theright side of the transfer box casing.3. Secure the backplate (including the oilcatcher) with the four special bolts and tightenusing a hexagonal socket to the specifiedtorque (see section 06-Torque values).4. Clean and fit brake drum and secure with twocountersunk screws to the specified torque(see section 06-Torque values).5. Adjust the parking brake. (Refer to Section 70Brakes or Section 10 Maintenance).- - -8. If adjustment is satisfactory remove the testequipment.,,’1.’c‘,,:.REVISED: JULY 88 35:‘..


yo;;; 1987 AUTOMATIC GEARBOXFAULT DIAGNOSIS: ZF4HP22 Automatic GearboxBefore referring to the fault diagnosis chart, ensurethat the following static checks are carried out first:INITIAL STATIC CHECKS.., ICheck start positionsReverse lightsGear engagementsFull throttleOil levelPressure test2000 rev/minIdle pressure‘P’ & ‘N’ only‘R’ onlyN-D,N-3,N-2,N-l,N-REngine switched off, check full travelat engine and at pedal.‘N’ selected, engine running at normalrunning temperature.150 k 5 p.s.i.100 _t 5 p.s.i. at 665 to 735 rev/min.FIT PRESSURE GAUGEService tools:18G502A-0-300 PSI (O-22 kg/cm*)pressure gauge.18C502-Flexible hoseLST502-I-Hose adaptorI. Drive the vehicle onto a suitable hoist.2. From beneath the vehicle, remove the plugfrom the bottom of the gearbox, fit theadaptor LST502-1 and tighten securely.3. Fit the hose to the adaptor and tightensecurely.4. Fit the gauge lSG502A to the other end ofthe hose and route to the interior of thevehicle, ensuring that the hose is fastenedclear of any rotating parts and exhaust pipes.._’,...‘.4.i.’5. Remove the vehicle from the hoist and carryout road test.. .Remove the pressure gauge6. Drive the vehicle onto a suitable hoist andthen reverse instructions 1 to 4.:


:.l-l 44 AUTOMATIC GEARBOXFAULT DIAGNOSIS-ZF4HP22 AUTOMATIC GEARBOX:TEST 1SYMPTOMINTERMITrENT DRIVEAND HIGH PITCHEDNOISEIFAULTLOW FLUID LEVELORRESTRICTED FILTER..TEST 2ISELECT ‘D’SYMPTOMNO DRIVE INREVERSEIISELECT ‘1’INO DRIVEDRIVES ORWARDINO ENGINE BRAKINGICONTINUEWITH TEST 3FAULTREVERSE GEARINTERLOCK VALVESEIZEDFAULTCLUTCH BRAKE DVEST3:SYMPTOMNO DRIVE FROM RESTWITH ‘D’ SELECTED,.:...:,NO DRIVEISELECT ‘1’VEHICLE DRIVESFAULTNO 2FREEWHEEL:CARRY OUT MAININO PRESSURENORMAL PRESSUREILOW PRESSUREFAULTCLUTCH AORPUMP FAILUREORSTICKING PRIMARYREGULATOR.i::.,.‘..‘.. :‘,. :;.,: .,’.:..::::Q


PO;;; 1987AUTOMATIC GEARBOXTEST 4INO PRESSUREIFAULTBLOCKED FILTERORPUMP FAILURESYMPTOMSLIP IN ALLFORWARD GEARSCARRY OUT MAIN LINE PRESSURECHECKIILOW PRESSUREIFAULTRESTRICTED FILTERSTICKING PRIMARYREGULATOR1NORMAL PRESSUREIFAULTCLUTCH ‘A’,TEST 5HIGH P ESSUREIFAULTPRIMARY REGULATORSEIZEDSYMPTOMHARSH ENGAGEMENT‘N’ TO ‘D’ICHECK ENGINEIDLE SPEEDICARRY OUTMAIN LINE PRESSURE CHECKIINORMAL PRESSUREIFAULTCLUTCH ‘A’ ORDAMPER FOR CLUTCH’A’TEST 6SYMPTOMFIERCE SHIFT OR FLARE., .+;.:.;, .,.. 1ST TO 2ND SHIFT :::g,.. .I .,CARRY OUTMAINLINE PRESSURE CHECKIIIHIGH PRESSURENORMAL PRESSUREFAdTSPOSSIBLEMODULATOR VALVE CLUTC!i BRAKE C’OR DAMPERSAND/ORCONTINUE FOR CLUTCH BRAKE CWITH TEST 5 CLUTCH BRAKE C’AND/ORCLUTCH BRAKE CiREVISED: JULY 88 3‘,.‘. ;.


-l 44 AUTOMATIC GEARBOX1987 ;;^d$;‘.‘,’.’’ ”,’ ,.: ;’1. ...:., ”‘.’ ,,..’ ‘::I’TEST 7HIGH GRESSUREICONTINUEWITH TEST 5SYMPTOMFIERCE SHIFT OR FLARE2ND TO 3RDtICARRY OUT MAIN LINEPRESSURE CHECKNORMAL ‘PRESSUREIFAULTSPOSSIBLE‘.MODJLATORVALVEORCLUTCH ‘8’ DAMPERCLUTCH ‘B’TEST 9SYMPTOMNO 3RD GEARIFAULTSPOSSIBLE2-i SHIFT CLUfCH ‘B’VALVETEST 9I4TH TO 3RD DOWNSHIFTVALVE SEIZEDOR3RD TO 4TH UPSHIFTVALVE SEIZED.SYMPTOMNO 4TH GEAR‘D’ SELECTEDIFAULTSPOSSIBLE1CLUTCH BRAKE F’. ..>. ,‘,.’ .;:.4 REVISED: JULY 88


R”o”v’;l:1987AUTOMATIC GEARBOXTEST 10NOTE:THE DIRECT DRIVE. . SYMPTOMCLUTCH WILL-ONLYNONE OR HARSH ENGAGEMENTENCAGE IF 4TH GEAR ISOF DIRECT DRIVE CLUTCHENGAGED SEE SECTION04 FOR LOCK-UP ANDUNLOCK SPEEDSAPPROPRIATE TO MODELYEAR.CARRY OUT ROAD TEST PRESSURECHECK WITH GAUGE CONNECTEDTO TORQUE CONVERTER.‘_,. .’PRESSURi NORMALIFAULTFAILED DIRECTDRIVE CLUTCHPRESSURES’CORRECTBUT REMAIN HIGHIFAULTSPOSSIBLEDlREdT DRIVE CLUTCH HYST:RESIS DIRECT DR;VE CLUTCHAND TORQUE CONVERTER VALVE SEIZED CONTROL VALVE SEIZEDC~JNTROL VALVE SEIZEDTEST 11rPRESSURE NORMALIFAULTGOVERNOR VALVESTICKINGIDIRECT DRIVE CLUTCHCONTROL VALVE STICKINGNOTE:DIRECT DRIVESYMPTOM - CLUTCH ENGAGEMENT ATDIRECT DRIVE CLUTCH SHIFTLOW SPEED WILL CAUSEPOINT INCORRECT OR AT LOWVlBRATlON IN THESPEEDTORQUECONVERTERICARRY OUTMAIN LINE AND TORQUE CONVERTERPRESSURE CHECKILOW OR INCORRECTPRESSUREIIHYSTERESISVALVE STICKINGIDIRECT DRIVE CLUTCHAND TORQUECONVERTERCONTROL VALVESTICKING:.:TEST 12SYMPTOMDRIVES IN ‘D’ ISTBUT IMMEDIATELYUPSHIFTS TO 3RDIFAULT2ND TO 3RD SHIFTVALVE SEIZEDREVISED: JULY 88 5:. .,


AUTOMATIC GEARBOX1987 ;;;;;;‘,TEST 13I1ST AND 2NDSHIFT VALVE SEIZEDSYMPTOMWITH ‘D’ SELECTEDVEHICLE STARTSIN 2NDIFAULTSPOSSIBLEIIGOVERNOR SLEEVESTICKING,. :.TEST 14SYMPTOMWITH ‘D’ SELECTEDVEHICLE STARTS IN 2ND OR 3RDWITH NO FURTHER UP OR DOWNSHIFTS‘.’:,IIGOVERNORIST TO 2ND ANDSLEEVE STICKING2ND TO 3RDSHIFT’ VALVES SEIZED:.,TEST 15SYMPTOMNO KICKDOWN4TH TO 3RDIFAULT4TH TO 3RD KICKDOWNVALVE SEIZED::.‘.’xTEST 16INCORREAT PRESSUREIFAULTSPOSSIBLEINCOPPRIMAR’ITHROlTLE VALVE REGULATORADIUSTMENTSTlCKiNGSYMPTOMUPSHIFTS/DOWNSHIFTSAND KICKDOWN SHIFTSAT INCORRECT ROAD SPEEDSICHECK THROlTLE KICKDOWNCABLE ADJUSTMENTICARRY OUT MAIN LINEPRESSURE CHECKNORMAL’PRESSURE.iFAULTSGOVERNOR VALVESTICKING“’,.,,,,I :6 REVISED: IULY 88


ot;; 1987AUTOMATIC GEARBOXTEST 17SYMPTOMNO UPSHIFTS AT LIGHTGOVERdOR VALVESTICKINGI .tSHIFT SALVESSTICKINGTEST 18SYMPTOMNO ENGINE BRAKING‘3’ SELECTED 3RD GEARIFAULTCLUTCH ‘C’..:.L;‘.\-,TEST 19IGOVERNOR VALVESTICKINGSYMPTOMDELAYED OR NO DOWNSHImOCCURS WHEN MAKING A MANUALSELECTION FROM ‘3’ TO ‘2’IFAULTSPOSSIBLEI 1‘2’ POSITION 2ND AND 3RDINTERLOCK VALVEUPSHIFT VALVESTICKINGSTICKINGTEST 20IGOVERNORSTICKINGSYMPTOMAT SPEEDS BELOW 28 MPHWHEN MAKING A MANUAL SELECTIONFROM ‘2’ TO ‘I’, DOWNSHIFTIS DELAYED OR DOES NOT OCCURIFAULTSPOSSIBLEI1ST TO 2NDSHIFT VALVEI‘1’ POSITIONINTERLOCK VALVESTICKING: -... ..:.:.REVISED: JULY 88


AUTOMATIC GEARBOX1987 ‘ANbtROVERTEST 21SYMPTOM‘1’ SELECTED 1ST GEARNO ENGINE BRAKINGIFAULTCLUTCH BAND 3TEST 22SYMPTOM‘2’ SELECTED 7ND GEARNO ENGINE BRAKINGIFAULTCLUTCH BAND 1TEST 23SYMPTOMVEHICLE DRIVESFORWARD IN ‘N’IFAULTCLUTCH ‘A’ SEIZED. _8 REVISED: IULY 88


RANGEROVERAUTOMATIC GEARBOXThe following repair instructions for the ZFautomatic gearbox are divided into three parts.Stage one covers repairs that can be made with thegearbox installed in the vehicle, stage two is withthe gearbox removed and stage three a majoroverhaul procedure.NOTE: Refer lo transfer box section for removalof transfer gearbox.LSTll6 -B clutch ‘0’ ring and snap ringreplacer.LSTll7 -Gear train remover and replacer.LSTl18 -Transmission holding fixture.LSTlOlG-1 -Adaptor clutch spring compressor.Gearbox DataAxial end float 0.2 to 0.4 mm (0.008 to 0.016 in).Service ToolsLSTlO8LST109LSTll 1LSTll2LSTl13LSTll4TX27TX3018G1501LSTll5-Rear oil seal replacer-Selector linkage setting gauge.-Oil pump rotation sleeve and endfloat gauge.-Kickdown cable remover.-Control unit inlet oil sealsremover/replacer.-Selector shaft oil seal replacer.-Torx bit.-Torx bit.-Torque converter remove/refithandles.-B clutch assembly puller hooks.From torque converter boss to torque converterhousing face SO mm (1.96 in).Freewheel cage assembly to ring gear; minimumclearance 0.1 mm (0.0039 in).Output shaft above cylinder F assembly; dimension10.00 mm (0.354 in).A cylinder protrusion above gearbox front face notmore than 8.5 mm (0.33 in).In addition to the above service tools, the followingitems should be manufactured locally to facilitatedismantling and re-assembly of the gearbox.TRANSFER AND AUTOMATICADAPTOR PLATEI6mmlt-;, (”.,.,:.‘.: :.::.:*:.76I!!I Sk-4 -id10.25-k -It; 16,. : :229-1- 6,0 I-260 -’ j“A” Centre of the Lif ting Hoist“B” Drill fixing holes to suit hoist table9.::’.A-:,‘. ‘. ,.I.;.’


AUTOMATIC GEARBOXINOTE: The fixture below can either be manufactured or purchased: fixture number LST 118.I-. iI(HIwc#tROVER.‘54I - - - ,265AUTOMATIC GEARBOX HOLDING FIXTURE:.,’‘.’.;‘.’ :.i.:RR1520M‘,..9. . .‘. ‘, ,;_:..‘. :.,:.?..’ ‘,’ .::_;


ROVERAUTOMATIC GEARBOX‘.’ .;: ,.RR524M.:1. GEARBOX ASSEMBLY2. INHIBITOR SWITCH ASSEMBLY3. CONTROL UNIT ASSEMBLY4. FILTER AND SUMP ASSEMBLY11


I 44 IAUTOMATIC GEARB0.X.’ .:aRR525M


. . .1. A CLUTCH ASSEMBLY2. B CLUTCH ASSEMBLY‘, :.:;.. ‘. :’._:,,c-‘. . .RR526M


44 AUTOMATIC GEARBOXRANGtROVER:1. C,C’ AND D CLUTCH ASSEMBLYRR527M1 4


RANtiEROVER AUTOMATIC GEARBOX b 11. FREEWHEEL AND FOURTH GEAR ASSEMBLY,l


AUTOMATIC GEARBOXRANGEROVER1. E AND F CLUTCH ASSEMBLY16RR529M


;;^d;‘;; 1987 AUTOMATIC GEARBOX 1441STAGE 1Inhibitor switch leak elimination1.2.3.4.5.6.7.Place vehicle on a suitable hoist or over a pit,open the hood and disconnect the batteryleads.From underneath the vehicle disconnect theinhibitor lead.Undo and remove the bolt and spring washer.Remove the retaining plate.Using a suitable tool remove the inhibitorswitch from the casing.Fit a new inhibitor switch, retaining plate ifexisting one is damaged, spring washer andbolt.Reconnect the inhibitor leads.Intermediate plate screw plugs leak elimination.NOTE: The following procedure is for all fourplugs on the plate. Seals that actually leakshould be replaced.1.2.Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batten/leads.From underneath the vehicle, using a suitablewrench remove the two hexagon headedplugs situated in the intermediate plate,catching any oil that may leak from the plate.. . .,. ,.A,..L. .c.wX4lkt3. Remove and discard the sealing rings.4. Fit new sealing rings and refit the plugs to thespecified torque.5. Using a suitable hexagon shaped tool, removethe two hexagon socket plugs, catching anyoil that may leak from the plate.6. Remove and discard the sealing rings.7. Fit new sealing rings and refit the plugs to thespecified torque.8. Connect the battery.9. Top up the gearbox with the correct oilthrough the filler level tube located within theengine bay. (See Section 09).10. Ensuring the vehicle is on level ground withthe parking brake applied check oil level whileengine is running at idle with neutral selectedafter selecting each gear.ContinuedREVISED: jtJLY88 17


AUTOMATIC GEARBOX1987 kANCltROVERSelector shaft leak elimination1. Place vehicle on a hoist or over a pit, openthe hood and disconnect the battery leads.2. From underneath the vehicle remove the nutand gear-change lever.3. Using a suitable tool remove the oil seal.4. Fit the new oil seal using the selector shaft oilseal replacer LST114. For ease of fitment use alight grease or Petroleum Jelly.5. Refit gear-change lever, ensure that it islocated correctly.6. Fit and tighten nut to the specified torque(see section 06-Torque values).Oil pan leak elimination1. Place vehicle on a suitable hoist or over a pitopen the hood and disconnect battery leads.2. From underneath the vehicle drain the gearboxusing a suitable container and remove the oilfiller level tube.3. Remove the six retaining plates and bolts.4. Remove the sump and discard the gasket.5. Inspect sump for wear or damage. Replace ifnecessary.6. Fit new gasket onto sump.7. Refit sump using the six retaining plates andscrews (two straight and four corner plates) tothe specified torque (see section OC-Torquevalues).RR903M8. Reconnect oil filler level tube, sump plug witha new seal to the specified torque (see sectionOC-Torque values).9. Connect the battery leads.10. Fill the gearbox with the correct oil (SeeSection 09).11. Ensuring the vehicle is on level ground withthe parking brake applied check oil level whileengine is running at idle with neutral selectedafter selecting each gear.NOTE: If leak persists and existing oil panhas been refitted, change the oil pan usingthe same procedure as above..,,18. ...:-: :. ,‘..; )...,.,. .,,,REVISED: JULY 8b


o;;; 1987AUTOMATIC GEARBOX 1441:Kickdown cable leak elimination1. Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batteryleads.2. Disconnect the kickdown cable from the rearof the engine.3. from underneath the vehicle, using a suitablecontainer drain the gearbox and discard thegearbox sump seal.4. Remove the oil filler level tube.5. Remove the six retaining plates and bolts.6. Remove the sump and discard the gasket.RR904M7.8.Remove the oil screen, undoing the threebolts using a TX27 Torx bit.Remove the control unit, undoing the thirteenremaining bolts using a TX27 Torx bit.9. Locate the selector cam and remove thenipple holding the kickdown cable from itsseat.10. Using the kickdown cable remover LST112remove the cable and it’s housing from thecasing and discard.11. Fit new throttle cable with new ‘0’ ring intothe casing.\ Y-T-.Continued19 :’.:.


I441 AUTOMATIC GEARBOX1987 ;-;;‘;I;12. Fit the nipple into the cam seat ensuring thatthe cam has been turned once before fitment.This will spring load the cam.13. Fit the control unit after cleaning the face witha lint free rag, ensuring the selector shaftlocates into the gear shift fork and fit thethirteen bolts loosely by hand.14. Place the selector linkage setting gaugeLST109 in position and gently press thecontrol unit in the direction as shown andtighten all thirteen bolts using TX27 Torx bit tothe specified torque (see section 06-Torquevalues).22.23.24.NOTE: The kickdown cable must beadjusted while the vehicle is running atidle.Adjust the cable sheath to achieve a crimp gapof 0.25 to 1.25 mm (.OlO to .050 in).Hold the cable sheath while tightening thelocknuts.Ensuring the vehicle is on level ground withthe parking brake applied, check oil level whileengine is running at idle with neutral selected,after selecting each gear.. . .:15. Remove setting gauge and fit oil screen usingTX27 Torx bit to the specified torque (seesection O6-Torque values).16. Refit sump with new gasket.17. Refit the six retaining plates and screws (twostraight and four corner plates) to thespecified torque (see section 06-Torquevalues).18. Reconnect oil filler tube and sump plug with anew seal to the specified torques (see section06-Torque values).19. Connect the battery leads.20. Fill the gearbox with the correct oil (seeSection 09).21. Connect the kickdown cable to the rear of theengine.,_.(,. ,.i20:.


o;;; 1987AUTOMATIC GEARBOX 144 1Extension case leak eliminationOil Screenix;.1. Remove the transfer box as described inSection 37.2. Using a suitable tool release the four boltsfrom inside the vehicle holding the transfergear selector housing and adaptor bracket.3. From underneath the vehicle using a suitabletool release the nine bolts holding theextension housing.4. Remove the extension housing and discard thegasket.5. Place extension housing on the bench andremove the oil seal.6. Ensure that all the surfaces are clean and thecase is free from damage. if damage has beenfound on the case, replace the case.7. If the case has to be replaced, fit the twodowels to the case.8. Fit a new gasket and oil seal using the rear oilseal replacer LSTI 08.1.2.3.4.5.6.7.8.9.10.11.12.Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batteryleads.From underneath the vehicle drain the gearboxusing a suitable container.Discard the sump plug seal ring.Remove the filler/level tube from the sump.Remove the six retaining plates and bolts.Remove the sump and discard the gasket.Using TX27 Torx bit undo the three screwswhich hold the oil screen.Remove the oil screen and discard the ‘0’rings.Separate the oil screen from the suction tubeand discard the ‘0’ ring and oil screen.Fit two new ‘0’ rings to the oil screen using alight grease for ease of assembly.Fit the suction tube to the oil screen.Fit the oil screen to the control unit andsecure with three bolts using TX27 Torx bittighten to the specified torque (see section06-Torque values).,RRQOBM9.10.11.12.13.Fit the extension case onto the gearboxensuring the oil seal is not damaged by theextension shaft.Fit and tighten the nine bolts to the specifiedtorque (see section 06-Torque values).From inside the vehicle refit the four boltswhich hold the transfer gear selector housingand adaptor bracket.Secure the four bolts to the specified torque(see section 06-Torque values).Refit the transfer box as described in Section37.RR6BlM13. Refit the sump using a new gasket.14. Secure using the six retaining plates and bolts(two straight and four comer plates), tightento the specified torque (see section 06-Torquevalues).15. Reconnect the oil level/filler tube to thespecified torque (see section 06-Torquevalues).16. Fit sump plug using a new seal to thespecified torque (see section 06-Torquevalues).17. Connect the batter)l leads.Continued21


. ...>.AUTOMATIC GEARBOX1987 KANG’ROVER18. Fill the gearbox with the correct oil throughthe filler/level tube located within the enginebay. (See Section 09).‘19. Ensuring the vehicle is on level ground withthe parking brake applied, cl-eck oil level whileengine is running at idle with neutral selected.5.6.7.8.Remove the six retaining plates and bolts.Remove the sump and discard the gasket.Using a TX27 Torx bit undo the three boltswhich hold the oil screen.Using a TX27 Torx bit undo the remainingthirteen bolts retaining the control unit.8Control UnitPlace the vehicle on a suitable hoist or over apit, open the hood and disconnect the batteryleads.From underneath the vehicle drain the gearboxusing a suitable container.Discard the sump plug seal ring.Remove the oil filler/level tube from the sump.AROOM9.10.Clean the surfaces ensuring no damage has . .occurred to the mounting face of the case,using a lint-free rag.Fit the new control unit ensuring the selectorshaft locates into the gear shift fork and fit thethirteen bolts loosely by hand.,_..I:RRSlOM Q 3.16.i22,:.:


;;“d;$ 1987AUTOMATIC GEARBOX 144111. Place the selector linkage setting gaugeLST109 in position and gently press thecontrol unit against the tool and tighten allthirteen bolts using TX27 Torx bit to thespecified torque (see section 06-Torquevalues).Oil Inlet Sealing Rings1.2.Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batteryleads.From underneath the vehicle drain the gearboxusing a suitable container.‘_.’,. ..12. Remove the setting gauge and fit the oilscreen using TX27 Torx bit to the specifiedtorque (see section 06-Torque values).13. Refit the sump using a new gasket.14. Secure with the six retaining plates and bolts(two straight and four corner plates), tightento the specified torque (see section OC-Torquevalues).15. Reconnect the oil filler/level tube to thespecified torque (see section 06.Torque16.17.18.19.values).Fit sump plug using a new seal to thespecified torque (see section 06-Torquevalues).Connect the battery leads.Fill the gearbox with the correct oil throughthe filler/level tube located within the enginebay. (See Section 09).Ensuring the vehicle is on level ground withthe parking brake applied, check oil level whileengine is running at idle with neutral selected,after selecting each gear.RR913M3. Discard the sump plug seal ring.4. Remove the oil filler/level tube from the sump.5. Remove the six retaining plates and bolts.6. Remove the sump and discard the gasket.7. Using a TX27 Tom bit undo the three boltswhich hold the oil screen.8. Using a TX27 Torx bit undo the remainingthirteen bolts retaining the control unit andremove the control unit.9. Clean the surfaces ensuring no damage hasoccurred to the mounting face of the case,using a lint-free rag.10. Using circlip pliers remove the eight circfipsand springs from the gearbox.11. Using control unit inlet oil sealsremover/replacer LST113 remove the eight oilseals.12. Clean the orifices and check for damage.NOTE: If damage has occurred replace thebox as described in Stage II.Continued


l-l 44 AUTOMATIC GEARBOX1987 ro;;;.: 13..*. ..:. .I’:.14.::...’:?#15.16.Using the control unit inlet oil sealremover/replacer LST113 fit the new sealsensuring they are seated fully home.Fit the eight compression springs, the fourshort ones at the front and the four long onesat the rear of the box.Using circlip pliers fit the eight circlips whichretain the compression springs.Fit the control unit ensuring the selector shaftlocates into the gear shift fork and fit thethirteen bolts loosely by hand.17.RAS8OMPlace the selector linkage setting gaugeLST109 in position and gently press thecontrol unit against the tool and tighten allthirteen bolts using TX27 Torx bit to thespecified torque (see section 06-Torquevalues).18. Remove the setting gauge and fit the oilscreen using TX27 Torx bit to the specifiedtorque (see section 06-Torque values).19. Refit the oil pan using a new gasket.20. Secure with the six retaining plates and bolts(two straight and four corner plates), tightento the specified torque (see section 06-Torquevalues).21. Reconnect the oil filler/level tube to thespecified torque (see section OC-Torquevalues).22. Fit sump plug using a new seal to thespecified torque (see sectionOCTorquevalues).23. Connect the battery leads.24. Fill the gearbox with the correct oil throughthe filler/level tube located within the enginebay. (See Section 09).25. Ensuring the vehicle is on level ground withthe parking brake applied, check oil level whileengine is running at idle with neutral selected,after selecting each gear.,.i_’24


Kl’ci’i/;i 1987AUTOMATIC GEARBOX 144 1Manual Valve Operating Mechanism1. Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batteryleads.2. From underneath the vehicle, using a suitablecontainer drain the gearbox and discard thegearbox sump seal.3. Remove the oil filler level tube.4. Remove the six retaining plates and bolts.5. Remove the sump and discard the gasket.6. Remove the oil screen, undoing the threebolts using a TX27 Torx bit.i. Remove the control unit, undoing the thirteenremaining bolts using a TX 27 Torx bit.7RR914~NOTE: The illustration for the followinginstructions is located at the top of thefollowing page.8. Locate the selector cam and remove thenipple holding the kick-down cable from itsseat.9. Remove the nut and gear change lever.IO. Using a suitable punch drift out the roll pinfrom the selector shaft and discard it.11. Using a suitable tool remove the selector shaftfrom the box, noting the position of thedetent plate.12. Remove the connecting rod complete withdetent plate, accelerator cam, spring and usinga suitable tool remove the oil seal and discard.13. Check all parts for wear or damage andreplace as necessary.14. Using selector shaft oil seal replacer LST 114,fit the oil seal. For ease of fitment use a lightgrease or Petroleum jelly.15. Fit connecting rod to detent plate and locatein the box by pushing the selector shaftthrough from outside of the casing.NOTE: The detent plate should go back intothe box in the same position as notedearlier.Continued”


. . . .AUTOMATIC GEARBOX1987 ;$;;;16.17.18.19.20.21.Fit the accelerator cam with the springFit the assembly into the box and secure it bypushing the selector shaft through.Align the hole in the selector shaft with thehole in the detent plate and secure with a newroll pin, using a suitable punch.Fit kickdown cable nipple into the cam seatensuring that the cam has been turned oncebefore fitment. This will spring load the cam.Fit the control unit ensuring the selector shaftlocates into the gear shift fork and fit thethirteen bolts loosely by hand.Place the selector linkage setting gaugeLSTl09 in position and gently press thecontrol unit against the tool and tighten allthirteen bolts using TX27 Torx bit to thespecified torque (see section OC-Torquevalues).22. Remove the setting gauge and fit oil screenusing TX27 Torx bit to the specified torque(see section 06-Torque values).23. Refit the oil pan with a new gasket.24. Refit the six retaining plates and screws (twostraight and four corner plates) to the25.26.27.28.specified torque (see section 06-Torquevalues).Reconnect the oil filler/level tube, sump plugwith new seal to the specified torques (seesection OC-Torquevalues).Connect the battery leads.Fill the gearbox with the correct oil. (SeeSection 09).Ensuring the vehicle is on level ground withthe parking brake applied, check oil level whileengine is running at idle with neutral selected,after selecting each gear.. . . .!26. .. . .


;Giii 1987 AUTOMATIC GEARBOXGOVERNOR HOUSING1. Remove the transfer box as described inSection 37.2. Using a suitable tool release the four boltsfrom inside the vehicle holding the transfergear selector housing and adaptor bracket.3. From underneath the vehicle using a suitabletool release the nine bolts holding theextension housing.4. Remove the extension housing ensuring thatthe seal is not damaged and discard thegasket.5. Remove the extension shaft and retaining boltwith ‘0’ ring.6. Remove the governor assembly with parkingwheel.7. Remove the two screws holding the governorhousing using TX27 Torx bit.8. Remove the governor housing complete anddiscard.9. Inspect the governor hub and parking wheelfor damage, if satisfactory, clean.10. Fit new governor housing complete togovernor hub and parking wheel using TX27Torx bit to the specified torque (see sectionOL-Torque values).11. Refit the governor assembly with parkingwheel onto the output shaft and push theassembly till fully seated.NOTE: To avoid damage to ‘0’ ring use alight grease or Petroleum Jelly. Ensure theseal rings are snapped together and areseated correctly.12. Fit the extension shaft, apply Loctite 270 tothe retaining bolt and using a new ‘0’ ring,tighten the bolt to the specified torque (seesection 06-Torque values).13. Fit new gasket onto rear of gearbox and fit theextension housing, taking care not to damagethe seal on assembly.14. Secure the extension housing using the ninebolts to the specified torque (see section06-Torque values).15. From inside the vehicle refit the four boltswhich retain the transfer gear selector housingand adaptor bracket.16. Secure the four bolts to the specified torque(see section 06-Torque values).17. Refit the transfer box as described in Section37.. .RR586M27‘..


AUTOMATIC GEARBOX1987 KANGEROVER.; .’ :,:.’-z,. ,..‘. ,.’.., ‘.. ‘.’XGOVERNOR HUB1. Remove the transfer box as described inSection 37.2. Using a suitable tool release the four boltsfrom inside the vehicle holding the transfergear selector housing and adaptor bracket.3. From underneath the vehicle using a suitabletool release the nine bolts holding theextension housing.15. Fit the parking wheel to the governor hubusing TX27 Torx bit to the specified torque(see section 06-Torque values).16. Fit three new seal rings onto the ‘F’ clutchhousing shaft and fit ‘0’ ring onto outputshaft.NOTE: For ease of fitment of the ‘0’ ringuse a light grease or Petroleum lelly.4. Remove the extension housing ensuring that 17. Fit governor assembly and parking wheel ontothe seal is not damaged and discard thethe output shaft and push the assembly tillgasket.fully seated.5. Remove the extension shaft and retaining boltwith ‘0’ ring and discard ‘0’ ring.NOTE: To avoid damage to ‘0’ ring use a6. Remove the governor assembly with parking light grease or Petroleum Jelly. Ensure thewheel.seal rings are snapped together and are7. Remove the two screws holding the governor seated correctly.housing using TX27 Torx bit.8. Using a TX27 Torx bit unscrew the two boltsand remove the parking wheel and discardgovernor hub.9. Remove the security clip and counter-weight.10. Remove the ‘0’ ring from off the output shaftand discard.11. Remove the three seal rings from the IF’ clutchhousing shaft.12. Inspect all parts for damage or wear, replace ifnecessary.13. Fit the counter-weight and security clip intothe new governor hub.14. Secure governor housing onto governor hubusing TX27 Torx bit to the specified torque(see section OC-Torque values).18. Fit new gasket onto rear of gearbox and fit theextension housing taking care not to damagethe seal or assembly.19. Fit the extension shaft and retaining bolt usinga new ‘0’ ring.20. Secure the extension housing using the ninebolts to the specified torque (see section06-Torque values).21. From inside the vehicle refit the four boltswhich retain the transfer gear selector housingand adaptor bracket. Secure the four bolts tothe specified torque (see section OC-Torquevalues). Refit the transfer box as described inSection 37.28‘.’::::


I.AUTOMATIC GEARBOXc,$‘,:..PARKING PAW1 MECHANISM1. Remove the transfer box as described inSection 37.2. Using a suitable tool, release the four boltsfrom inside the vehicle holding the transfergear selector housing and adaptor bracket.3. From underneath the vehicle, using a suitabletool, release the nine bolts holdmg theextension housing.NOTE: The illustration for the followingreplacement is located at the top of theiollowing page.4. Remove the extension housing ensuring thatthe seal is not damaged and discard thegasket.5. Remove the extension shaft and retaining boltwith ‘0’ ring, discard the ‘0’ ring.6. Remove the governor assembly with parkingwheel.8.13 _15.16.17.18.19.20.NOTE: Take care when removing theassembly. Do not damage parts which-couldweaken spring tension.IO. Inspect all parts for wear or damage andreplace if necessary.11. Fit the pin and the leg spring ensuring that thespring is located correctly.12. Fit the paw1onto the pin and the spring leginto the hole 111the pawl. This creates tensionin the spring.13. Fit the plate and guide plate using TX27 Torxbit to the specified torque (see sectionO&Torque values).14. Refit the governor assembly with parkingwheel onto the output shaft and push theassembly till fully seated.NOTE: To avoid damage to ‘0’ ring use alight grease or Petroleum jelly. Ensure theseal rings are snapped together and areseated correctly.Fit new gasket onto rear of gearbox and fit theextension housing, taking care not to damagethe seal or assembly.Fit the extension shaft and retaining bolt usinga new ‘0’ ring.Secure the extension housing using the ninebolts to the specified torque (see section06-Torque values).From inside the vehicle refit the four boltswhich retain the transfer gear selector housingand adaptor bracket.Secure the four bolts to the specified torque(see Section 06-Torque values).Refit the transfer box as described in Section37.7. Remove guide plate bolt, using TX27 Torx bit.8. Remove the plate and guide plate from thegearbox case.9. Remove the pin, pawl and the spring.REVISED: IULY 88 2 9::j...


AUTOMATIC GEARBOX1987 ‘ANGtROVER,I: STAGE II,’ ”WARNING: Where the use of a transmissionhoist is necessary, it is ABSOLUTELY ESSENTIALto follow the hoist manufacturers instruction toensure safe and effective use of the equipment.ZF Gearbox-Remove and refit..IRemoving1. Install the vehicle on a hydraulic hoist.'. 2. Open the hood.3. Disconnect the battey leads.4. Release the airflow meter to plenum chamberhose.5. Disconnect the kickdown cable from throttlelinkages located on the throttle lever bracketryat the rear of the plenum chamber. Removethe transmission dipstick.6. Remove the fan cowl from the radiator.7. From inside the vehicle remove the fourscrews securing the glove box liner to theglove box and lift out the liner.8. Carefully pry the window lift switch panel awayfrom the front of the glove box. Identify eachswitch connection for re-assembly, disconnectthe plugs and remove the switch panel.9. Remove the main and transfer gearbox knobs.10.NOTE: Refer to Automatic GearSelector-Panel Illumination in Section86.Electrical, page 27, for the removal andrefit of the main gear selector lever.Carefully pry the centre panel out of the floormounted console and remove it from thevehicle.13.141516Carefully maneuver the console assembly awayfrom the radio housing and remove it from thevehicle.Release the large nut retaining the parkingbrake outer cable to the top of the gearboxtunnel.Remove the nut and feed the cable throughthe hole in the tunnel to the underside of thevehicle.Raise the vehicle on the hoist and drain thegearbox.NOTE: The illustration for the followingremoval instructions is located at the top ofthe following page.17. Release the nut and clamp securing thespeedometer cable to the rear of the transferbox.18. Withdraw the cable from the speedometerdrive pinion.19. Release the cable from the clips at the side ofthe gearbox.20. Release the four nuts and bolts securing therear drive shaft to the rear output flange andtie the shaft to one side.21 Remove the four nuts and bolts securing thefront drive shaft to the front output flange andtie the shaft to one side.22 Release the nuts and bolts securing the frontdown-pipes to the front catalysts.23. Release the nut at the rear tailpipe bracket,disconnect the catalysts from the downpipes,and tie the rear tail pipe and muffler to oneside.11. Release the two bolts and two screws securingthe console assembly to the gearbox tunnel.12. Release the parking brake and remove thecotter pin, clevis pin and washer securing theparking brake cable to the parking brake lever.3 0 REVISED: JULY 88:.”


PO;;; 1989 AUTOMATIC GEARBOXVRRlQQ5E24.25.26.27.Disconnect the oil filler tube from the front ofthe gearbox oil pan.Disconnect the two oil cooler pipes from therear of the gearbox bellhousing.Remove the bolts securing the cross-memberin position, using suitable equipment expandthe chassis and withdraw the cross-member.Remove the front cover from the bottom ofthe torque converter housing. Remove oneconverter drive bolt. Mark both the flexibledrive plate and the torque converter to ensurethe unit is reassembled in the original buildposition. Remove the remaining three bolts.31.32.33.34.35.36.37.38.39.Remove the nuts and bolts holding rearleft-hand side, mounting bracket to chassis.Remove the nuts and bolts holding right-handside mounting bracket to chassis.Lower the jack until the rear brake drum clearsthe rear passenger footwell.Remove the cotter pin and washers securingthe differential lock lever to the connectingrod, and disconnect the lever from the rod.Disconnect the electrical leads from thedifferential lock switch and neutral warningswitch.Remove the breather pipe from the top of thetransfer gearbox.Using a suitable floor jack support the rear ofthe engine.Remove the torque converter housing toengine bolts.Carefully withdraw the gearbox and transferbox from the engine taking care not todamage any seals.Continued .:28. Disconnect the inhibitor switch.29. Disconnect the selector linkage.30. Attach the transmission jack using the adaptorplate (illustration RR739M).REVISED: MAY 89 31‘.,,


AUTOMATIC GEARBOX1989 RANG’ROVER. .Refitting40. Reverse the removal instructions.Observe the following points:Ensure that the torque converter and flexible plateare in their original positions.41. Refill the gearbox with the correct grade andquantity of oil (see Section 09).Kickdown cable adjustment42. Kickdown cable must be checked and adjustedas follows:NOTE: The kickdown cable must beadjusted while the vehicle is running atidle.43. Adjust the outer cable to achieve a crimp gapof 0.25 to 1.25mm t.010 to .050 in) dimensionA.44. Hold the outer cable while tightening thelocknuts.RR2286E50. Tighten the outer cable clamp to 22 - 28Nm(16 - 21ft lb).51. Reconnect the battery leads.52. Ensuring the vehicle is on level ground withthe parking brake applied, check the oil levelwhile engine is running at idle with neutralselected, after selecting each gear.There are several places where leaks can occurat the front of the gearbox. The following areremedies for curing any one of these problems.Eliminating leaks/replacing Torque Converter.:.‘.RA2080EGear lever selector cable setting45. Remove the split pin and washer securing thetrunnion to the gear change lever at thegearbox and disconnect the trunnion from thelever.46. Select neutral gear at the gearbox using thegear change lever.47. Release the clamp securing the outer selectorcable, the clamp is attached to a bracketwhich is mounted on the side of the gearboxextension housing.48. Select neutral gear. at the gear shift, within thevehicle.49. Rotate the trunnion clockwise or counterclockwise, until the trunnion will engage withthe gear change lever at the gearbox, fit thetrunnion and secure in position using a NEWcotter pin and washer.1. Remove the gearbox/transfer box assembly aspreviously described.2. Place the gearbox on the bench using thetorque converter handles 18G1501, removethe torque converter, taking care not todamage the torque converter/oil pumphousing oil seal.3.: Replace with new torque converter usingtorque converter handles 18G1501, checkingthat the dimension from the converter fixingbolt boss to the converter housing face is 50mm (1.96 in). If this dimension is achieved theconverter is properly seated in the housing.4. Refit the gearbox and transfer box assembly aspreviously described.RR892~-.3 2 REVISED: MAY 891..:.,.


R”o”v’;rf. 1989AUTOMATIC GEARBOX;:._: ‘I’._1.Eliminating Leaks on the Pump HousingRemove the gearbox/transfer box assembly aspreviously described.2. Place the gearbox on the bench and removethe torque converter using torque converterhandles 18G1501, taking care not to damagethe converter/oil pump housing oil seal.4.5.6.Remove bellhousing and pump assembly fromgearbox case and discard the gasket.Remove the eight hexagonal bolts on the rearof the pump.Screw in two of the bolts, diagonally oppositeeach other, tap lightly using a soft headedmallet; this will free the pump assembly fromthe intermediate plate.3. Remove the twelve hexagonal bolts (inner ringpattern).7. Remove the shaft sealing ring and ‘0’ ringfrom the pump housing and discard.8. Using oil seal replacer l-ST108 fit the shaft sealring into the pump housing.9. Fit the ‘0’ ring onto the circumference of thepump housing.10. Align the dowel with its hole in theintermediate plate and press the pumphousing home.33


AUTOMATIC GEARBOX1989 KANCItROVER11. Secure the pump housing to the intermediateplate using the eight hexagonal bolts andtighten to their specified torque (see section06-Torque values).12. Place the bellhousing and intermediate plateassembly on the bench, front face up. Usingthe oil pump rotation sleeve LSTI 11, checkthat the pump gears rotate freely.13. Before replacing the intermediate plate andbellhousing assembly, check that the thrustwasher and axle cage are seated on the Aclutch housing.14. Place the gasket and disc washer onto thebeilhousing and intermediate plate assemblyusing a light grease or Petroleum lelly.15. fit bellhousing and intermediate plateassembly onto gearcase and secure with thetwelve hexagonal bolts tightened to thespecified torque (see section 06-Torquevalues).16. Place the end float gauge LSTIII onto thepump housing and check that the axial play isbetween 0.2-0.4 mm (0.008 in to 0.016 in). Ifthe end float is excessive or tight, replaceexisting washer, situated at the rear of theintermediate plate, with a suitable washer togive the required end float as stated above.17. Refit torque converter into housing usingtorque converter handles 18Gl501, checkingthat the dimension from the converter fixingbolt boss to the converter housing face is 50mm (1.96 in). If this dimension is achieved theconverter is properly seated in the housing.18. Refit the gearbox/transfer box assembly aspreviously described.Eliminating leaks between gearbox housing andintermediate plate.I. Remove the gearbox/transfer box assembly aspreviously described.2. Place the gearbox on the bench and removethe torque converter using torque converterhandles 1t3G1501, taking care not to damagethe converter/oil pump housing-oil seal.3. Remove the 12 hexagonal bolts tinner ringp a t t e r n ) .4. Remove the bellhousing intermediate plateassembly from gearbox case and discard thegasket.34:; :‘.


;;^d;‘;l; 1989AUTOMATIC GEARBOX‘. . :::.,’ :..,.IRR57SMr.“.,.’,..X,c:.., t: I,*.: :,..1:5. Place new gasket onto intermediate plateusing a light grease or Petroleum Jelly.6. Before replacing the intermediateplate/bellhousing assembly check that thethrust washer and axle cage are seated on theA clutch housing.7. Fit bellhousinglintermediate plate assemblywith disc washer onto gearcaseand securewith the hvelve hexagonal bolts tightened tothe specified torque (see section 06-Torquevalues).8. Place the end-float gauge LSTlll onto thepump housing and check that the axial play isbetween 0.2-0.4 mm (0.008 in to 0.016 in). Ifthe end-float is excessive or tight, replaceexisting washer, situated at the rear of ?heintermediate plate, with a suitable washer togive the required end-float as stated above.9. Refit tclque converter into housing usingtorque converter handles 18G1501, checkingthat the dimension from the converter fixingbolt boss to the converter housing case is 50mm (1.96 in). If this dimension is achieved theconverter is properly seated in the housing.10. Refit the gearbox/transfer box assembly aspreviously described.Continued.i


-44 AUTOMATIC GEARBOX,1989 RANGEROVERReplacing Bellhousing1.2.Remove the gearbox/transfer box assembly aspreviously described.Place the gearbox on the bench and using thetorque converter handles 18G1501 remove thetorque converter, taking care not to damagethe converter/oil pump housing oil seal.Refit the torque converter into the housingusing torque converter handles 18C1501,checking that the dimension from theconverter fixing bolt boss to the converterhousing face is 50 mm (1.96 in). If thisdimension is achieved the converter isproperly seated in the housing.Refit the gearbox/transfer assembly aspreviously described.REPLACING PUMP1. Remove the gearbox/transfer box assembly aspreviously described.2. Place the gearbox on the bench and removethe torque converter using torque converterhandles 18C1501, taking care not to damagethe converter/oil pump housing oil seal.RR997M3. Remove the eighteen hexagonal bolts.4. Remove bellhousing.5. Fit new bellhousing.6. Secure bellhousing with the eighteenhexagonal bolts to the specified torque (seesection 06-Torque values).3. Remove the twelve hexagonal bolts (inner ringRR899M3 6


PO;;; 1989AUTOMATIC GEARBOX4.5.6.Remove bellhousing and pump assembly fromgearbox case and discard the gasket.Remove the eight hexagonal bolts on the rearof the pump.Screw in two of the bolts, diagonally oppositeeach other, tap lightly using a soft headedmallet; this will free the pump assembly fromthe intermediate plate.10.1112Fit new pump assembly aligning the dowelwith its hole in the intermediate plate andpress the pump housing home.Secure the pump housing to the intermediateplate using the eight hexagonal bolts andtighten to their specified torque (see section06-Torque values).Place the bellhousing and intermediate plateassembly on the bench, front face up. Usingthe oil pump rotation sleeve LSTlll, checkthat the pump gears rotate freely.Remove bellhousing and pump assembly fromgearbox case and discard the gasket.Place the new gasket and disc washer ontothe bellhousing and intermediate plateassembly using a light grease or PetroleumJelly.Fit bellhousing and intermediate plateassembly onto gearcase and secure with thetwelve hexagonal bolts tightened to thespecified torque (see section 06-Torquevalues).RR57BM5.8.iContinued37’ ,’: .,.:


i44 AUTOMATIC GEARBOX1989 rUINbtROVER13.Place the end-float gauge LSTlll onto thepump housing and check that the axial play isbetween 0.2-0.4 mm (0.008 in to 0.016 in). Ifthe end-float is excessive or tight, replaceexisting washer, situated at the rear of theintermediate plate, with suitable washer togive required end-float as stated above.3. Remove the twelve hexagonal bolts (inner ringpattern).*1NOTE: If damage is apparent to the boltsthey should be replaced.I$!14.15.Refit the torque converter into the housingusing torque converter handles 18Gl501,checking that the dimension from theconverter fixing bolt boss to the converterhousing face is 50 mm (1.96 in). If thisdimension is achieved, the converter isproperty seated in the housing.Refit the gearbox/transfer box assembly aspreviously described.Replacing Intermediate Plate1. Remove the gearbox/transfer box assembly aspreviously described.2. Place the gearbox on the bench, and removethe torque converter using torque converterhandles 18C1501, taking care not to damagethe torque converter/oil pump housing oilseal.4.5.6.NOTE: The illustration for the followingreplacement instructions is located at thetop of the following page.Remove bellhousing and pump assembly fromgearbox case and discard the gasket.Remove the eight hexagonal bolts on the rearof the pump.Screw in two of the bolts, diagonally oppositeeach other, tap lightly using a soft headedmallet; this will free the pump assembly fromthe intermediate plate....RR578M7. Remove the ‘0’ ring from the pump housingand discard.8. Place the bellhousing and intermediate plateassembly on the bench, front side up.38:


7,166;17II9. Remove the six remaining hexagon bolts andremove the bellhousing from the intermediateplate assembly.10. Remove the four screw plugs and seal ringsfrom the intermediate plate, discard the sealrings.11. Remove the oil cooler pipe adaptors and fitthem into the new intermediate plate.12. Fit plugs and new seal rings into the newintermediate plate.13. Fit intermediate plate assembly onto thebellhousing.14. Secure with six hexagonal bolts (outer ringpattern) and tighten to the specified torque(see section 06-Torque values).15. Place intermediate plate and bellhousingassembly on bench, front face up.16. Fit the ‘0’ ring onto the circumference of thepump housing.17. Align the dowel with its hole in theintermediate plate and press the pumphousing home.18. Secure the pump housing to the intermediateplate using the eight hexagonal bolts andtighten to the specified torque (see section06-Torque values).19. Place the bellhousing and intermediate plateassembly on the bench, front face up. Usingthe oil pump rotation sleeve LSTI 11, checkthat the pump gears rotate freely.20. Before replacing the intermediate plate andbellhousing assembly check that the thrustwasher and axle cage are seated on the Aclutch housing.21. Place the gasket and disc washer onto thebellhousing and intermediate plate assemblyusing a light grease or Petroleum Jelly.22. Fit bellhousing and intermediate plateassembly onto gearcase and secure with thetwelve hexagonal bolts tightened to thespecified torque (see section OC-Torquevalues).23. Place the end-float gauge LSTIII onto thepump housing and check that the axial play isbetween 0.2-0.4 mm (0.008 -0.016 in). Ifend-float is incorrect, replace existing washer,situated at the rear of the intermediate plate,with suitable washer to give required end-floatstated above.24. Refit the torque converter into the housingusing torque converter handles 18Cl501,checking that the dimension from theconverter fixing bolt boss to the converterhousing face is 50 mm (1.96 in). If thisdimension is achieved the converter isproperly seated in the housing.25. Refit the gearbox/transfer box assembly aspreviously described.39


AUTOMATIC GEARBOXRANGElg8’ ROVER,. .,’AUTOMATIC GEARBOX-OVERHAULRemove Torque Converter1. Place gearbox into the transmission holdingfixture LSTIIB and tighten.2.NOTE: Refer to Stage II Section for removalof the gearbox from the vehicle.NOTE: Care must be taken not toover-tighten as casing will distort.Using the torque converter handles 18Gl501remove the converter from the bell housing.Remove Valve Body1. Turn the gearbox upside down in the fixture.2. Remove the six bolts and retaining plateswhich hold the oil pan.3. Remove the oil pan and rubber seal anddiscard seal.4. Using Torx bit TX27, unscrew the three Torxheaded bolts which hold the oil screen andremove. Separate the oil screen from thesuction tube and discard the two ‘0’ rings andoil screen.CAUTION: Ensure no damage occurs to thepump bush and seal ring lip when removing thetorque converter. The converter is still full of oileven after the gearbox has been drained, so careshould be taken when removing the unit.:.:. ”,,’:_: 40.:...1. :“‘.:..


R”d;;; 1989AUTOMATIC GEARBOX I44 15. Using Torx bit TX27, unscrew the thirteen Torxheaded bolts which retain the valve block tothe gearbox.8. Remove the eight sealing rubbers using toolLST113 and discard.9. Remove the circlip, spring and using the toolLST113 remove the restrictor at the rear of thegearbox.Remove Parking Pawl and Governor6.:. Y,. 7.Using circlip pliers remove the eight circlips.Remove the eight springs (four short springs atthe front of the gearbox and four long springsat the rear of the gearbox).1.2.3.4.5.6.7.Engage ‘Park’ position.Using a suitable wrench unscrew the couplingshaft bolt and remove the ‘0’ ring.Remove the coupling shaft.Remove the nine bolts and washers from theextension housing.Remove the extension housing and gasketfrom the gearbox and discard the gasket.Disengage ‘Park’ position.Withdraw the parking wheel and governorhub...::’_’ II_.’‘. :RR91BM’ 3.iRRSllMContinued,’. . ,.I‘. ::::4 1‘: :.


RANGEAUTOMATIC GEARBOX “*’ ROVER8.9.Unscrew the bolt which retains the guide plateusing Torx bit TX27.Disengage the spring and remove, also the pinand pawl.NOTE: Take care when removing theassembly. Do not damage parts which couldweaken the spring tension.Remove inhibitor SwitchLJsing a suitable wrench remove the bolt andspring washer.Remove the retaining plate.Using a suitable tool remove the inhibitorswitch from the casing.Discard switch if damaged.,RR92tM10. Using Torx bit TX30 remove the ten Torx boltsfrom the rear of casing.Remove Bell Housing and Intermediate PlateI. Using a suitable socket wrench remove thetwelve bolts (inside diameter bolt pattern)holding the bell housing. . . .RR53254.',', ,:::.,.,:,a,.42


$j;;; 1989 AUTOMATIC GEARBOX, . . 2.3.Remove the bell housing and intermediateplate assembly complete, and discard thegasket.Remove the thrust washer, axle bearing anddisc washer from the input shaft.NOTE: Under normal vorking conditionsthere is no need to separate the bellhousing from the intermediate plateassembly. If damage has occurred to eitherthe bell housing or intermediate plate seethe appropriate section.3. Remove inner carrier A, disc, axial bearing andthrust washer.Remove B Clutch AssemblyRemove A Clutch Assembly1. Turn gearbox with front facing upwards.2. Remove input shaft and A clutch assemblyfrom gearbox.mI. Using two suitable screwdrivers remove thesmall snap ring in cylinder 6.2. Using the B clutch assembly puller hooksLSTllS remove the B clutch assembly.NOTE: To remove assembly, lift up cylinderB until it stops, push agsembly back downand lift up again using more weight.Continued43 ‘(: :..


AUTOMATIC GEARBOXKANGt“*’ ROVER:*:.3. Remove disc, axial bearing and thrust washer.Remove 4th Gear Assembly1. Turn gearbox to the horizontal position.2. Push assembly out from the rear, guiding itfrom the front of the casing.3. Remove support ring and ‘0’ ring.Remove C, C’ and D Clutch Assembly7. Using a suitable screwdriver remove centreplate snap ring via a hole in the casing.,.:2. Using tool LSTll7 attached to intermediateshaft remove C, C’ and D clutch assembly.,:.,.:,4 4


R”o”v’;l:1989 AUTOMATIC GEARBOX I44 1Transmission Gear Selector Assembly andKickdown CableRemove and overhaul‘_.’:,,..”1. Remove the kickdown cable from the cam.2. Using kickdown cable remover LST112,remove the kickdown cable from the casing.3. Using a punch remove the roll pin from theselector shaft.4. Using a pair of pliers or grips pull the selectorshaft from the casing.5. Remove the stop washer, connection rod, camand leg spring.6. Using a screwdriver pry out the seal ringlocated in the gearbox casing and discard.7.NOTE: At this stage the gearbox is totallystripped.Inspect and clean casing ensuring no damagehas occurred.? 89. Fit connection rod into the stop washer.10. Place stop washer with connection rod intothe gearbox casing and then feed the selectorshaft into the casing.11. Fit the leg spring onto the cam.12. Place the assembly into the gearbox casingand push the selector shaft through until thehole in the shaft aligns with the hole in thestop washer.13. Using a suitable punch, fit roll pin with theopen side facing the rear of the gearboxcasing.14 Fit new kickdown cable assembly into its seaton the gearbox casing.RR915MAssemble8. Fit new seal ring into gearbox casing usingselector shaft oil seal replacer LST114.RR540M.i15. Fit the nipple of the kickdown cable into thecam seat ensuring the cam has been turnedone revolution to load the spring.NOTE: After gearbox has been refittedcheck the kickdown cable and gear selectoradjustments are correct. (See kickdowncable adjustment and gear lever selectorcable setting)..’:::,‘>, ‘: ‘.’ ,.: ‘.REVISED: DEC. 87 45. .,:.


lKANtit44 AUTOMATIC GEARBOX lg8’ ROVERFit Inhibitor Switch1.2.Fit new inhibitor switch if existing one wasdamaged.Replace retaining plate and fix with springwasher and bolt, securing tightly.9. Using pliers and screwdriver remove thesnap-ring on carrier E.10Turn the assembly around and remove theoutput shaft from ring gear by pushing thegear downwards.4th Gear Assembly Overhaul1. Using soft-jawed vice secure the 4th gearassembly by gripping the output shaft.2. Remove the sungear.3. Remove the planet gear assembly.NOTE: Removal of snap-ring on assembly isnot necessary unless damage has occurred.4. Remove the disc washer, axial bearing andthrust washer.5. Remove assembly from the vice and turnupside down onto the bench.6. Remove cylinder F from cylinder E.7. Remove cylinder E from the freewheel 3rd.8. Remove axial disc, cage and two thrustwashers.11.12.13.14.15.16.NOTE: Do not remove the snap-ring onoutput shaft.Place ring gear on bench, teeth side down.Remove carrier E from the ring gear assembly.Remove the freewheel cage assembly from thering gear by using an upward turning motion.Remove the snap-ring retaining the freewheelring (inner) to the hollow gear.Remove the freewheel ring (inner) from thehollow gear.Remove freewheel cage from freewheel ring(outer).NOTE: Care should be taken whenremoving the freewheel ring, which due tothe rollers and springs becoming loose mayfall out...,46 REVISED: DEC. 87


R”o”v’;l;1989AUTOMATIC GEARBOX17. Remove the snap-ring retaining the clutchplates and steel plates in cylinder F.18. Remove four clutch plates and five steel platesfrom cylinder F.19. Using clutch spring compressor LST1016-I,press down on the spring plate and removethe split rings.23. Remove the snap ring from cylinder E.24. Remove the four clutch plates and five steelplates from cylinder E.25. Using clutch spring compressor LST1016-1,press down on the spring plate and removethe split rings.26. Remove the pressure plate.27. Remove piston E by using air pressure directedinto the oil feed hole.:.:.,::RR543MI20. Remove the spring plate.21. Turn the cylinder upside down, using twosmall punches placed in the holes(diametrically opposite each other), pushdown and remove the piston.22. Remove and discard the two ‘0’ rings fromthe piston.NOTE: The five sealing rings do not need tobe removed on the cylinder unless anydamage has occurred to them.I28. Remove and discard the two ‘0’ rings fromthe piston.WARNING: Before using an air line ensure allnecessary safety precautions are taken toprevent personal injury, i.e., safety glasses,protective clothing etc.NOTE: Do not remove the snap-ring at thebottom of the E cylinder, unless damaged.Continued


AUTOMATIC GEARBOXRANGElgag ROVER‘YI,_..’:I. . . . .‘. ‘.. -48I ‘.‘..,. .‘,


48,49,52,54,55 43-41/36,38,43,55,56,- 35~~~ \NJ,41 37,3830 29,y. 34,35,570:::


AUTOMATIC GEARBOX1989 KANGtROVERAssemble29. Fit three seal rings on the outside hub andtwo seal rings on inside hub of cylinder F ifthey have been removed.NOTE: Ensure each seal ring is snappedtogether.40.41.42.30. Fit new ‘0’ rings onto the F piston. 43.31.32.33.34.35.NOTE: For ease of assembly applyPetroleum jelly on ‘0’ rings and stretch theinner ‘0’ ring to avoid damage oninstallation.Fit piston F into cylinder F.Fit spring plate using clutch spring compressorLST116-1. 44.Fit the two halves of the split ring to securethe spring plate in position, then remove theclutch spring compressor.Install the clutch plates and steel plates intothe F cylinder starting with a steel plate thenclutch plate finishing up with the end platewhich is thicker than the normal steel plates.Fit the snap-ring into cylinder F to retain theclutch plate assembly.NOTE: Do not confuse the steel plates of Fclutch with that of the E clutch. Thedifferences are thus: F clutch-steel platesare thicker and the end plate has no innerteeth.Fit spring plate using clutch spring compressorLSTl016-1.Fit the two halves of the split ring to securethe spring plate in position then remove theclutch spring compressor.Install the clutch plates and steel plates,starting with a steel plate then clutch plate,finishing up with the end plate which is thickerthan the normal steel plates.Fit the snap-ring into cylinder E to retain theclutch plate assembly.NOTE: Do not confuse the steel plates of Eclutch with that of the F clutch. Thedifferences are thus: E clutch-steel platesare thinner and the end plate has innerteeth.Fit the freewheel ring (inner) to the hollowgear.45. Secure using the snap-ring.46. Fit freewheel cage into the freewheel ring(outer), and press home.47. Turn the freewheel cage in the freewheel ring(outer) until rim of the cage has been seated.48. Fit carrier E to freewheel cage assembly.49. Fit freewheel cage assembly to ring gearassembly using a clockwise motion.50. A minimum clearance of 0.1 mm (0.0039 in)should be obtained between the freewheelcage assembly and ring gear.36.37.38.39.Fit new snap-ring at bottom of cylinder E if ithas been removed.Fit the two ‘0’ rings onto the E piston.NOTE: For ease of assembly applyPetroleum Jelly.Fit E piston into cylinder E.Fit the pressure plate with ‘depression’ facingdownwards.50RR545M.,‘. %,j ‘>. . . . .‘1 ‘,,:’50::


ot;; 1989AUTOMATIC GEARBOX.( .: _.I.:. . . .51.52.53.54.Inspect the output shaft for damage to thesnap-ring, if any, replace snap-ring; alsoremove ‘0’ ring and discard, replace with new‘0’ ring.Align inner teeth of carrier E with freewheelring (inner) teeth and then place freewheel 3rdassembly onto the output shaft.Secure snap-ring into position, retaining thefreewheel 3rd.Fit the steel thrust washer and then thecopper thrust washer onto the freewheel 3rdassembly.58. When correctly mounted the raised edge ofthe output shaft will be 10.00 mm (0.393 in)above the top surface of cylinder F assembly.NOTE: Disengagement of end plate andfreewheel ring (inner) will occur if end playexceeds 3.00 mm (0.118 in).55.Fit cylinder E onto freewheel 3rd assemblyusing a turning motion, ensuring that the teethof the end plate line up with the freewheelring touter).:,:. .*56.57.NOTE: When correctly assembled, copperthrust washer must be touching cylinder Eassembly. The cylinder E assembly will turnin a clockwise direction when holding theoutput shaft. If the cylinder E assembly isturned in a counter clockwise direction thefreewheel will lock up.Fit the axial cage and axial disc onto the rearof cylinder E.Using a turning motion, fit cylinder F assemblyonto cylinder E assembly.RR546M59.60.Fit the complete 4th gear assembly into thegearbox, ensuring that the oil feed holes incylinder F line up with the correspondingholes in the gearbox casing.Secure the 4th gear assembly to the gearboxusing ten countersunk screws. Tighten screwsto the specified torque using Torx bit TX30(see section 06-Torque values)./I61.62.63.64.65.NOTE: If screws are not tightened correctly,clutch pressure will be lost in clutch F.Turn the gearbox so that the front of the caseis uppermost. .iFit the disc washer, axial cage and thrustwasher onto the 4th gear assembly.Fit the seal ring onto the planetary case andsnap together if ring has been removed.Fit the planetary set into the hollow gear usinga turning motion.Fit the sun gear onto the planetary set.Continued51 ‘.: :,(


.*r-1 44 AUTOMATIC GEARBOX: Refit park mechanism Brakes C, C’ and D with planetary sets-overhaul1. Turn gearbox into a horizontal position.2. Fit leg spring over pin and place into rear of. . gearbox.3. Fit paw1onto pin, to tension spring fit leg ofspring into hole of pawl.4. Fit plate and guide plate and tighten tospecified torque using Torx bit TX27 (seesection 06-Torque values).1.2.3.4.5.6.7.0.Remove the centre plate assembly.Remove the two brake C’ clutches and twosteel plates from cylinder C-D.Remove freewheel 2nd complete.Remove the two brake C’ clutches and threesteel plates from cylinder C-D.Remove the cylinder C-D with brake Dassembly.Remove the support ring from the planetarysets assembly.Remove the front planetary set with freewheelassembly.Remove the sunshaft from the assembly.NOTE: Do not remove the seai ring fromthe sunshaft unless damaged.5. Turn gearbox so that the front of the case isuppermost.6. Fit the disc and axial cage.9. Remove the snap-ring from the hollow gear.10. Remove the hollow gear from the assembly.11. Remove the rear planetary set.12. Remove the thrust washer and axial bearing.13. Remove the intermediate shaft with the hollowgear complete.14 Remove the axial bearing and two thrustwashers, one from each side of the bearing.15 Remove the distance ring.NOTE: The snap-ring in the webshaft needonly be removed if damaged.. . ..i52:.‘.‘. :\


nAUTOMATIC GEARBOX 44,’-44 20 23‘B 9 lo 11 16. .12A00 c:;.RR550M16. Holding the hollow gear with the rear faceuppermost, remove the snap-ring.17. Disconnect the hollow gear from theintermediate shaft.18. Remove the external snap-ring from the brakeD assembl),.19. Remove the four clutch plates and five steelplates from the assembly.20. Using clutch spring compressor LSTlO16-1press down on the spring plate to remove thesplit rings.21. Turn cylinder C-D upside down and using theclutch spring compressor, remove thesnap-ring with pliers. .i22. Remove the spring plate.Continued:. .53.‘.,.


KANGtiAUTOMATIC GEARBOX “*’ ROVER23. For ease of removal of both piston C andpiston D, use air pressure fed through the oilfeed holes.WARNING: Before using an air line ensure ailnecessary safety precautions are taken toprevent personal injury, i.e., glasses, protectiveclothing etc.24. Discard ‘0’ rings from both piston assemblies.25. Using the clutch spring compressor removethe spring plate, as previously explained, fromthe centre plate assembly.26. To remove the piston use air pressure aspreviously described and discard ‘0’ rings.Assemble27.28.29.30.31.Secure the webshaft into a soft-jawed vice.Fit the snap-ring if it has been removed intothe lower groove.Fit the distance ring into the webshaft.Place a disc washer and axial cage into theassembly.Assemble together the hollow gear with theintermediate shaft and secure with thesnap-ring.32. Place the other disc washer onto the rear ofthe intermediate shaft using grease.33. Fit the intermedrate shaft assembly Into thewebshaft ensuring the disc washer mates upto the axial cage.34. Using a turning motion fit the rear planetaryset Into the hollow gear.35. Fit the front hollow gear into the webshaftassembly and secure with a snap-ring.36. insert disc washer and axial cage.37. Place support ring onto the webshaftassembly.38. Tap the two fitting pegs down into the slotson the side of the cylinder C-D if they havebeen removed.39. Place the two ‘0’ rings onto piston D.NOTE: For ease of assembly, applyPetroleum jelly to the ‘0’ rings.37/29 2fJ 27.33I..(’ \I. ..” :


R”o”v’;l:1989AUTOMATIC GEARBOX48,49,50,51RR552M,.--40. Fit the D piston into cylinder C-D ensuringthat the correct side is selected, that is, theside with the least number of slots in cylinderC-D.41. Fit the spring plate and using the clutch springcompressor LST1016-I, fit the snap-ring intothe groove.42. Place the two ‘0’ rings onto piston C.NOTE: For ease of assembly, wPJYPetroleum Jelly to the ‘0’ rings.43. Fit the C piston into cylinder C-D.44. Using the clutch spring compressor LST1016-1,fit the spring plate and the two halves of thesplit rings.45. With the clutch D opening uppermost, fit theplanetary set with freewheel 1st gear onto thehub of cylinder C-D.46. Fit the clutch plates and steel plates startingwith a steel plate then a clutch plate, finishingup with the thin end plate.47. Fit the snap-ring on the outside of the C-Dcylinder which secures the D clutch assembly.48. Fit two seal rings onto the sunshaft and snaptogether if they have been removed.49. Fit the sunshaft into the planetary set, splinesfirst.50. Turning the whole assembly around so the Cclutch side is uppermost, fit the assembly intothe webshaft assembly.51. Fit freewheel second onto the sunshaft, beforefitting align the upper and lower halves.52.NOTE: To ensure correct fitment of thefreewheel second, the top of the assemblyis marked with the word ‘OBEN’Fit the C clutch plates and steel plates startingwith a steel plate then a clutch plate into thelonger slots of C-D cylinder..:Continued55 . .1.., ‘.i. .., .*


AUTOMATIC GEARBOXKANGElg8’ ROVER.53.54.Fit end plate which has three groups of threeteeth, of which the middle tooth must fit into!he short slots in the C-D cylinder.Fit the C’ clutch assembly starting with aclutch plate ending with a steel plate.NOTE: When fitting these plates ensureteeth on the outside do not go into the ‘V’shaped area of the C-D cylinder.If thin steel plates have to be added intothe C or C’ clutch assembly ensure thatthese plates are placed on the side nearerto the respective pistons.57I 55 I IiS55. Fit the two ‘0’ rings onto the piston C’.NOTE: For ease of assembly, use PetroleumJelly.56. Fit C’ piston assembly into centre plate.57. Using clutch spring compressor LSTl016-I, fitspring plate and the two i~alves of the splitrings.58. Place the centre plate onto the C-D cylindermaking sure that the 'V' shape in the platelocates in the ‘V’ shaped hollow in the C-Dcylinder.59. Remove the C, C’ and D clutch assembly fromvice and place a greased thrust washer to therear face of the webshaft.60. Fit the whole assembly into the transmissioncase using the gear train remover/replacerLST717, ensuring that the oil feed holes arealigned with those in the bottom of thecasing.61. Secure the whole assembly with a snap-ringwhich fits into the groove inside the casing.6056


R”o”v’;s; 1989AUTOMATIC GEARBOX 144 1Clutch B OverhaulNOTE: The illustration for the followingoverhaul instructions is located at the topof the following page.Place B clutch assembly with open faceupwards.Remove the snap-ring from inside theassembly.Remove the four clutch plates and five steelplates.Using clutch spring compressor LSTl 016-l)depress spring plate and remove snap-rrng andretaining washer.5. Remove the spring plate.6. For ease of removal of the piston B, use airpressure fed through the oil feed hole, thenturn assembly upside down and tap lightly onthe working surface.WARNING: Before using an air line ensure allnecessary safety precautions are taken toprevent personal injury, i.e., safety glasses,protective clothing etc.7. Remove and discard the two ‘0’ rings onpiston Et.8. Remove seal ring on bottom of B cylinder ifdamage has occurred.Assemble9. Fit the two ‘0’ rings onto piston B.NOTE: For ease of assembly use aPetroleum Jelly.10. Install piston B into cylinder 6.11. Place spring plate into cylinder B and usingclutch spring compressor LSTl 016-l) fitretaining washer (lips facing upward) andsnap-ring.12. Fit the clutch and steel plates starting with asteel plate finishing with the steel plate withthree sets of three teeth grouped together.13. Fit snap-ring into the clutch B assembly.14. Turn upside down and fit seal ring and snaptogether if removed.15. Install B clutch assembly into the transmissioncase, clutch plates facing upwards.16. Using B clutch ‘0’ ring and snap-ring replacerLST116, fit ‘0’ ring, support ring and finally thesnap-ring.Continued,:; .+.I,.. .‘,57‘.


I 44 IAUTOMATIC GEARBOX9,lORR559Mi..:58


Al,JTOMATlC GEARBOXA Clutch Assembly Overhaul1. Remove the input shaft by holding the Aclutch assembly firmly and pushing the shaftagainst the working surface. Remove the ‘0’ring and discard.2. Using a suitable press, depress the A-B carrierand remove the snap-ring.3. Remove carrier A-B.4. Remove the six clutch plates and seven steelplates, plus two wavy spring plates fitted tolater transmissions.NOTE: If there is evidence of clutch slip orif the plates are worn, replace the clutchunit using the latest type.RR561M \/5. Remove spring plate.6. For ease of removal of piston A, use airpressure fed through the oil feed hole.WARNING: Before using an air line ensure allnecessary safety precautions are taken toprevent personal injury, i.e., safety glasses,protective clothing etc.7. Remove and discard both ‘0’ rings on pistonA.Continued ”REVISED: DEC. 88


1441AUTOMATIC GEARBOXAssemble8. Fit the two ‘0’ rings onto piston A.9. Pidce the piston into cylinder A.10. Fit the spring plate into the cylinder A with theconvex side facing the piston.11. Placing carrier A-B on the bench, fit the clutchunit. If the latest clutch unit is being fitted, seeRR2669E for the correct build sequence. Notealso that one steel plate is of alternativethickness.12. Fit carrier A-B with the clutch assembly ontocylinder A.13. Using a suitable press, depress the A-B carrierand secure with the snap-ring.14. Fit the two seal rings, if removed, and an ‘0’ring onto the input shaft.15. Fit the input shaft into the cylinder A assemblyand press downwards until shaft meets thestop.1989 r;;‘;r;16. Fit the thrust washer onto the input shaft seat.NOTE: Use Petroleum Jelly to retain washerin place.17. Install the inner carrier A onto the intermediateshaft within the gearbox.18. Place the disc washer and axial cage into theinner carrier A.19. Fit cylinder A assembly into the gearbox usinga right to left twisting motion. This will enablethe teeth of the clutch plates to mesh into theA-B carrier and inner carrier...L .FRICTIONA RZ669E1RR562M6 0REVISED: DEC. 88


‘. .‘. :.y$,R”;;; 1987AUTOMATIC GEARBOXNOTE: When properly engaged the top ofthe cylinder A should not protrude morethan 8.5 mm (0.33 in) above the gearboxfront face.20. Place the thrust washer and axial cage ontothe A cylinder.4.5.Remove the six remaining bolts situated onthe inside of the bell housing.Separate the bell housing from theintermediate plate.Pump, Intermediate Plate and Bell HousingPump Assembly._d.,.Remove and OverhaulPlace the bell housing on the bench, openface down.Remove the eight hexagonal bolts on the rearof the pump.Screw in two bolts, diagonally opposite eachother, tap lightly using a soft-headed mallet,this will free the pump assembly from theintermediate plate.6.7.8.Using a suitable tool remove the shaft sealingring and ‘0’ ring from the pump housing anddiscard.Strip, inspect and clean the pump assemblyusing a lint-free rag.NOTE: If damage has occurred to theassembly, replace the whole pump.Replace the pump hollow gear and pump gearinto pump housing with the marked side ofgears facing upwards.Continued61


9. Fit the ‘0’ ring onto the circumference of thepump housing.10. Using oil seal replacer LSTlOB, fit the shaft seairing into the pump housing.11. Fit the alignment pin into the pump housing.NOTE: If damage is found replace theintermediate plate.15. Fit the oil cooler pipe adaptors.16. Fit the four screw plugs into their correctlocations with new ;eal rings.lo-‘_,’..’. .15RR566MIntermediate Assembly12. Remove the four screw plugs and seal ringsfrom the plate and discard the seal ring.13. Remove the oil cooler pipe adaptors.14. inspect and clean the intermediate plate with alint-free rag.62/:., .:.,..::: : ‘.;


AUTOMATIC GEARBOXRR568MRefit bell housing, intermediate plateassemblyand pump17. Inspect and clean the bell housing.NOTE: If damage is found replace the bellhousing’18. Align the dowel in the pump with its hole inthe intermediate plate and press the housinginto position.19. Secure the pump housing to the intermediateplate with the eight hexagonal bolts andtighten to the specified torque (see section06-Torque values).20. Using the oil pump rotation sleeve LSTlllcheck that the pump gears rotate freely.21. Place the gasket and disc washer onto theintermediate plate assembly using a petroleumjelly.22. Fit the intermediate plate onto the gearbox.23. Fit the bell housing onto the intermediateplate assembly.24. Secure with the six short bolts which locateon the outside diameter ring pattern withinthe bell housing and the twelve long boltswhich are located in the inner diameter ringpattern. Tighten all the bolts to the specifiedtorque (see section 06-Torque values).ContinuedREVISED: DEC. 87 63:..


24RR570M” ,25. Using the end-float gauge LSTlll check theaxial clearance 0.2 to 0.4 mm (0.008 to 0.016in). If the axial clearance is not achieved,remove the bell housing/intermediate plateassembly complete and replace existing discwasher using a thicker or thinner onedepending on the reading first taken.Re-assemble bell housing/intermediate plateand check the axial clearance once again.Repeat this operation until axial clearance hasbeen achieved.Checking Axial ClearanceExtension Housing and Governor-Overhaul1. Remove the two bolts using Torx bit TX27retaining the parking wheel.2. Remove the clip and counterweight frominside the governor hub.3. Remove the two bolts from the top of thegovernor hub which releases the housing anddiscard.4. Release the retaining clip and discard.5. Remove the pin, spring, piston and weightfrom the governor housing.6. Clean and inspect all parts for damage.1. Fit LSTlll end-float gauge onto the outputshaft, making sure the outer shaft engagesinto the pump.2. Pressing the output shaft towards the rear ofthe gearbox and tighten the three screws onthe gauge.3. Measure the clearance and note.4. Now secure the remaining screw which retainsthe outer shaft to the inner collar.5. Pull the whole assembly away from the bellhousing, measure the clearance and note.6. Subtract the first measurement from thesecond to obtain the axial clearance.NOTE: Replace any part which may bedamaged.7. Remove the seal ring from the extensionhousing.8. Clean and inspect the extension housing fordamage.NOTE: If the dowels are damaged replacethe dowels only. If extension casing isdamaged replace the case and dowels.9. Inspect and clean extension- shaft and bolt fordamage, replace if necessary.1,’iREVISED: DEC. 87


..!.’R”o”v’;;;1987AUTOMATIC GEARBOX (44 1‘.,..;.:


AUTOMATIC GEARBOX1987 kANCItROVERRefit Valve Body, Oil Pan and Torque Converter1. Position the gearbox so that the bottom isuppermost.2. insert the eight sealing bushes into the oilfeed holes using the control unit inlet oil sealremover/replacer LST113.6. Fit the restrictor, spring and circlip usingLST113 into the hole adjacent to the four rearA.:,WARNING: Before using an air line ensure allnecessary safety precautions are taken toprevent personal injury, i.e., safety glasses,protective clothing etc.3.4.5.As a test to check the tunctron oi the clutchand brake assemblies, insert an air gun intothe oil feed holes and exert a pressure of S to6 bar (72.5 to 87 p.s.i.).Fit the four short springs into the oil feedholes at the front of the gearbox and fourlong springs into the oil feed holes at the rearof the gearbox.Fit the eight circlips to retain the springs andsealing bushes.7.8.Place the control unit ensuring the selectorshaft locates into the gear shift fork and fit thethirteen bolts loosely by hand.Place the selector linkage setting gaugeLST109 in position and gently press thecontrol unit in the direction shown and tightenall thirteen bolts using Torx bit TX27 to thespecified torque (see section OC-Torquevalues).‘.. RR573MREVISED: DEC. 87


yo;;; 1987AUTOMATIC GEARBOX9. Remove the setting gauge and fit the suction.’ ‘,hose and ‘0’ ring to new oil screen.10. Fit the new oil screen with new ‘0’ ring andsecure with the three bolts using Torx bit TX27to the specified torque (see section 06-Torquevalues).:... 11. Fit the oil pan using a new gasket.12. Secure the oil pan with the six retaining plates(two straight and four corner plates), tightento the specified torque (see section 06-Torquevalues).13. Fit oil pan plug with a new seal.16.17.18.19Refit the gearbox to the vehicle.Refill the gearbox with the correct quantity ofrecommended fluid.Reconnect the battery ground terminal.Ensuring that the parkbrake is applied, selectneutral gear in the main gearbox and start theengine. While the vehicle is idling in neutral,select all forward and reverse gears and returnthe gear selector to neutral. Check the fluidlevel in the gearbox, if necessary, top up tobetween the maximum and minimum levels onthe dipstick. Recheck the fluid level.,_..,.14. Turn the gearbox around until the gearbox ishorizontal.15. Using the torque converter remove/refithandles 18ClSO1, install the torque converterinto the gearbox.NOTE: Check that the dimension from theconverter fixing bolt boss to the converterhousing face is 50 mm (1.96 in). If thisdimension is achieved the converter isproperly seated in the housing.I .,,,/. ;REVISED: DEC. 87 67 ,,.’


:,.:.*.” ,. . i


o;;; 1989AUTOMATIC GEARBOX 144 1p, t.4ZF MAIN GEARBOX AND BORG WARNER TRANSFER GEARBOX - ADAPTOR PLATETo assist in the removal of the transmission assembly from the vehicle it is necessary to locally manufacturean adaptor plate to use in conjunction with a transmission hoist.NOTE:Four holes (A) to be countersunk on underside to suit hoist.r-50 DIA. B 12.7HOLE THRO’:s O-13 DIA. 0 t&3ioILL2 HOLES THRO’.33 DIA,El 6A C/SINKUNDERSIDEContinued.’ .,:.,:,. .’ADDITION: SEPT. 8869:


l-l 44 AUTOMATIC GEARBOX 1989 HANbtROVERRR2562EA: Centre of the lifting hoistx: Drill fixing holes to suit hoist tableMaterial: Steel plate BS 1449 Grade 4 or 14 (Mild Steel).. . .ADDITION: sEPT. 88:.,..,, . .


PO;:; 1989AUTOMATIC GEARBOXZF MAIN GEARBOX AND BORG WARNERTRANSFER GEARBOXRemove and refitPreparation - under bonnetWARNING: Where the use of a transmissionhoist is necessary, it is ABSOLUTELY ESSENTIALto follow the hoist manufacturer’s instructions toensure safe and effective use of the equipment.1. Place the vehicle on a hydraulic hoist andchock the road wheels.2. Disconnect the battery negative terminal.3. Release and remove the fan blade assembly.Note the assembly has a left hand thread.4. Release the clamp and remove the air intakehose from the neck of the plenum chamber.5. Disconnect the kickdown cable from thethrottle linkage.6. Release the two gearbox breather pipes fromthe clip located on the lifting eye at the rearof the right hand cylinder head.7. Remove the gearbox dipstick.RR2578M13 Release the two bolts and two screws securingthe glove box/console assembly to thegearbox tunnel.‘. “”Inside the vehicle8. Select low range, unscrew and remove thetransfer gearbox knob.9. Unclip the top cover of the main gearboxselector and remove the circlip, withdraw thedetent button. Remove the circlip above theselector knob retention nut, remove the nut,serrated washer and withdraw the selectorknob.10. Carefully pry the inset panel out of the floormounted console, complete with gear selectorillumination panel and ashtray. Disconnect theelectrical multi - plug to the graphics panel,and remove the inset panel.11. Release the four screws and remove the glovebox liner.12. Carefully pry the window lift switch panel fromthe front of the glove box. Push the panelcomplete with switches back through thepanel opening and place on the gearboxtunnel.14. Detach the two relays from the inner side ofthe glove box.15. Disconnect the electrical leads to the rearcigar lighter.16. Disconnect the parkbrake cable from theparkbrake lever. Raise the lever ;+J~zsimultaneously detaching thebox/console assembly from the lower dash.Remove the assembly from the vehicle.17. Remove the retaining clip and pull theparkbrake adjustment thumb wheel from theouter sleeve. Push the inner sleeve to theunderside of the vehicle.18. Remove the sound deadening trim from thetop of the gearbox tunnel.19. Remove the screws and detach the retainingplate from around the transfer gearbox lever.ContinuedADDITION: SEPT. 88 71


AUTOMATIC GEARBOXRANGElg8’ ROVER‘.: ”Under the vehicle 25.20.21.Raise the hydraulic ramp.Remove the main and transfer gearbox oildrain plugs. Where applicable remove the fillerplug to assist draining and drain the oil intosuitable containers. While the oil is drainingcontinue with the following operations.26.27.28.29.30.31.32.Release the two clamps at the side of theengine sump that secure the two gearbox oilcooler feed and return pipes.Place a suitable container below the gearbox,disconnect the oil cooler feed and returnpipes from the bottom and side of thegearbox. Plug the pipes and openings toprevent ingress of foreign matter.Disconnect the dipstick tube from the front ofthe gearbox oil pan.Mark each drive shaft flange at the transfergearbox with an identification line to aidre-assembly. Remove the fasteners anddisconnect the propeller shafts at the outputflanges. Tie the shafts to one side.Release the nut and disconnect thespeedometer cable from the rear outputhousing, tie the cable to one side.Disconnect the main gearbox selector cableand rod from the left side of the gearbox. Laythe cable aside.Disconnect the main gearbox inhibitor switchmulti - plug from the main harness.If fitted disconnect the speed transducer multi- plug from the main harness..’ .’‘\Remove the transmission assembly33. Remove the nine front cover plate bolts fromthe bottom of the gearbox bellhousing.Detach the cover plate to gain access to thefour torque converter tixing bo!ts.P22.23.Disconnect the multi - plugs to the Lambdasensors.Remove the front exhaust down pipes andintermediate pipe complete with centremuffler.NOTE: The above operation will require theassistance of a second mechanic to supportthe exhaust system while the variousfasteners are released.24.Remove the eight bolts securing the crossmember. Note it may be necessary to spreadthe chassis to enable the cross member to bewithdrawn.72 ADDITION: SEPT. 88


R”“$“;i 1989AUTOMATIC GEARBOX‘.I,, :34.35.36.Rotate the engine using the crankshaft pulleyuntil two of the access holes in the driveplate/ring gear assembly are visible through thebell housing bottom cover opening.Remove the two bolts that are visible throughthe access holes, which secure the drive plateto the torque converter. Mark one of theaccess holes and a bolt hole in the converterwith an identification line to aid re - assemblyand to maintain original build setting.Rotate the crankshaft 180” until the remainingaccess holes are visible. Remove the remainingtwo bolts.44.45.Remove the bellhousing bolts noting that oneof the bolts also secures the gearbox dipsticktube.Withdraw the transmission assembly from theengine, ensuring that the torque convertor isremoved with the gearbox and does not stayon engine.Refitting46.47.48.49.Refitting the gearbox is a reversal of theremoval procedure noting the followingpoints.The flexible drive piate to torque converterbolts are to be coated with Loctite 270 priorto assembly.Tighten all fasteners to the specified torquevalues.New gaskets are to be fitted to the exhaustflanges, all joints other than those fitted withdoughnuts, to be coated with exhaust sealer.Check the system, if any leaks are evidentreseal as necessary.1.RR2544EI’;, .(‘._‘..:,‘,‘, .: ; 1:. ., 1.37. Position a suitable transmission floor jack onthe rear output housing or brake drum tosupport the weight of the transmissionassembly.38. Remove the bolts and withdraw the transfergearbox mountings.39. Fit the previously manufactured fixture on atransmission hoist, raise the hoist and positionthe fixture and hoist under the transfergearbox mounting points.40. Using the original gearbox mounting boltssecure the fixture to the gearbox.41. Remove the transmission floor jack from therear of the transfer gearbox.42. Carefully lower the transmission until the topof the transfer gearbox clears the rearpassenger footwell.43. Position the transmission floor jack under theengine to support the weight while thebellhousing bolts are removed.ADDITION: SEPT. 8873 .’ ”y :;. . ::


. . .,i


,...:PO;;; 1987DRIVE SHAFTS. .DRIVE SHAFTS - OVERHAULNOTE: Rear drive shafts fitted to early modelshave a universal joint assembly with an internalsplined bore which moves along the outside ofthe main drive shaft spline.Later models have a re-designed rear drive shaft,the universal joint assembly has been modifiedto incorporate a splined shaft which movesinside a hollow drive shaft, refer to theillustrations for identification as to which driveshaft is fitted to the vehicle.The design change does not affect the overhaulof the yoke and spider assemblies.REAR DRIVE SHAFTRRlQQQEREAR DRIVE SHAFf: NEW CONDITIONRR2277MRR2276M‘_4. Unscrew the dust cap and withdraw the slidingmember.RR227BMDismantle1. Place the vehicle over a pit or on a suitablehoist.2. Undo the 8 nuts and using the sliding joint,remove the drive shafts from the vehicle.3. Note the alignment markings on the yoke andthe drive shaft (front), sliding member and thedrive shaft (rear).FRONT DRIVE SHAFTRR1999E5. Clean and examine the splines for wear. Wornsplines or excessive back-lash will necessitatedrive shaft replacementRRlQ97ERR2000E/,,’IREVISED: SEPT. 87 1:/, ‘. ’


1471 DRIVE SHAFTS1987 pgv;;6.7.Remove paint, rust, etc., from the vicinity ofthe universal joint bearing cups and circlips.NOT?: Before dismantling the drive shaftjoint, mark the position of the spider pinlubricator relative to the journal yoke earsto ensure that the grease nipple boss isre-assembled in the correct runningposition to reduce the possibility ofimbalance.Remove the &clips, and grease nipple.Assemble12.13.14.15.16.171819Remove the bearing cups from the newspider.Check that all needle rollers are present atidare properly positioned in the bearing cups.Ensure bearing cups are one-third full of freshlubricant. See Recommended Lubricants.Enter the new spider complete with seals intothe yokes of the sliding member flange.Partially insert one bearing cup into a flangeyoke and enter the spider trunnion into thebearing cup taking care not to dislodge theneedle rollers.Insert the opposite bearing cup into the flangeyoke. Using a vice, carefully press both CUPSinto place taking care to engage the spidertrunnion without dislodging the needle rollers.Remove the flange and spider from the vice.Using a flat faced adaptor of slightly smallerdiameter than the bearing cups press each cupinto its respective yoke until they reach thelower land of the circlip grooves. Do not pressthe bearing cups below this point or damagemay be caused to the cups and seals.RR2001ENOTE: When replacing joints use only03EHD series replacement spider packs.8. Tap the yokes to eject the bearing cups.20 FII Itre c-rrclips.21 t II


PO;;; 1987DRIVESHAFTSt., ”,.. 22. Lubricate the sliding member splines and fitthe sliding member to the drive shaft ensuringthat the markings on both the sliding memberand drive shaft align.23. Fit and tighten the dust cap.24. Fit the grease nipples to the spider and thesliding member and lubricate.25. Apply instructions 15 to 20 to the oppositeend of the drive shaft.26. Fit the grease nipple and lubricate.NOTE: FRONT DRIVE SHAFT:On refitting the front drive shaft it should benoted that the drive flange at the sliding jointend of the shaft is to be fitted to the driveflange at the front end of the transfer gearbox.KEY TO SPIDER ASSEMBLY1. Circlip2. Bearing cup3. Nylatron washer4. Needle rollers (27 per cup)5. Seal retainer6. Seal;.;y .,5 ,’:REAR DRIVE SHAFTOn refitting the rear drive shaft the drive flangeat the sliding joint end of the shaft is to befitted to the brake drum at the rear of thetransfer gearbox.27. Fit the drive shaft to the vehicle and tighten tothe specified torque (see section 06-Torquevalues).REVISED: JUNE 87


_.:..:::v : : :., ., .:.: ;_ .: _- . . .,, ..‘....’ ). . ..)


$1;; 1987REAR AXLE & FINAL DRIVEREAR AXLERemove and RefitRemovingWARNING: The removal and refitting of the axlefrom the vehicle requires the assistance of afurther two personnel to steady the axle, whenlowering or repositioning the axle.1. Drain the brake system.2. Jack-up the rear of the vehi’cle and support thechassrs.3. Remove the road wheels.4. Support the axle weight with a suitablehydraulic jack.5. Disconnect the shock absorbers.6. Disconnect the flexible brake hose at theconnection under the floor, ensuring anyexcess of fluid is stemmed.7. Disconnect the pad wear multi-plug at thebracket mounted on the underside of thefloor. Pry the rubber grommet out of thebracket and feed the plug through the hole.8. Disconnect the lower links at the axle.9. Mark the differential and drive shaft driveflanges with identification marks to aidre-assembly. Remove the four nuts and bolts,lower the drive shaft and tie it to one side.10. Disconnect the pivot bracket ball joint at theaxle bracket.11. Release the bolts and remove the coil springretaining plates.12. Lower the axle and remove the road springs.13. Withdraw the axle assembly.Refitting14. Position t.he axle and fit the lower links, andtighten the bolts to the specified torque (seesection 06-Torque values).15. Reverse the removal instructions.16. Tighten the pivot bracket ball joint to axle tothe specified torque (see section 06-Torquevalues).17. Tighten the drive shaft to differential driveflange to the specified torque (see section06-Torque values).18. Refill the brake system and bleed as describedin Section 70.REVISED: MARCH 90 1‘,..


OVERHAUL AXLE DIFFERENTIAL ASSEMBLYService Tools:1861295 -Flange holder tool18C191 -Pinion height setting gauge186191-4 -Universal setting block18647-6 -Pinion head bearing remover/replacerLST106 -Oil seal replacerR0262757A -Extractor for pinion bearing racesR0262757-1 -Replacer-use with R0262757AR0262757.2 -Adaptor tail bearing cap replacerR0530105 -Wrench flange and carrier bearingnutsR0530106 -Bracket for dial gauge andindicatorMS47 -Press7. Remove the cotter pin securing the pinionflange nut.8. Remove the pinion flange nut using servicetool 18C1205 to restrain the flange.DISMANTLEIt is essential that differential components aremarked in their original positions and relative toother components so that, if refitted, their initialsetting is maintained. Note that the bearing capsmust not be interchanged.1.2.3.4.5.6.Remove the axle shafts then the differentialassembly from the axle.Drive out the roll pin securing the bearing nutlocking fingers to the bearing caps. Removethe locking fingers.Loosen the bearing cap bolts and mark thecaps for re-assembly.Using service tool R0530105, remove thebearing adjusting nuts.Remove the bearing cap bolts and bearingcaps.Lift out the crown wheel, (ring gear)differential unit and bearings.ST&M /9.10.Withdraw the pinion complete with pinionhead bearing and outer bearing shims.Withdraw the shims.Remove the pinion flange oil seal, spacer andbearing. Discard the oil seal.‘\ST506M.:1- A,,2 REVISED: MARCH 90


FOE; 1989REAR AXLE & FINAL DRlVE11. Using service tool R0262757A, remove thepinion head bearing track and shim and driveout the outer bearing track from thedifferential housing.nST509MINSPECTIONRR2666EtY12. Remove the pinion head bearing with servicetool MS47 and adaptor 18G47-6.18. Check all bearings for wear and/or pitting.19. Check all gears for wear, scuffing, pitting anddamaged teeth.20. NOTE: The crown wheel and pinion aresupplied as a matched set, also the pinionhousing and bearing caps.ASSEMBLE,.Differential gears21. Fit the differential gears to the differentialhousing.22. Fit the differential cross shaft and retainingcirclips..,,ST508H13. Remove the bolts and washers securing thecrown wheel to the differential flange.Withdraw the crown wheel.14. Remove the differential carrier bearings.15. Remove the circlips securing the differentialcross shaft. Extract the cross shaft.16. Withdraw the differential gears and pinions.17. Thoroughly clean all components.ST 5lOMREVISED: DEC. 883‘.. .


REAR AXLE & FINAL DRIVE1989 “R^o”v’;;r;23.24.25.26.Check the gear for freedom of rotation andbacklash. Nominal backlash should be present.Excessive backlash will necessitate replacementof the gears and/or the differential housing.No provision is made for backlash adjustment.Check that the serial number marked on thepinion end face matches that marked on thecrown wheel.Ensuring that the differential housing flangeand crown wheel are thoroughly clean fit thecrown wheel.Fit the carrier bearings using a suitable pressor drift and assemble the tracks traces) to thebearings.2530.31.32.33Tighten the bearing cap bolts to the specifiedtorque (see section 06-Torque values).Using a dial gauge check the crown wheel forrun-out. This should not exceed 0.10 mm(0.004 in). If excessive run-out is recordedremove the crown wheel and examine crownwheel and mounting flange for burrs, grit, etc.Refit the crown wheel and recheck. Run-out,attributable to a buckled or damageddifferential housing flange can be correctedonly by replacing the differential gear housing.When satisfied that run-out is within thespecified limits remove the differential housingfrom the pinion housing.Remove the crown wheel bolts and refit themusing Loctite ‘Studlock’. Evenly tighten thebolts to the specified torque (see section06-Torque values).26‘.,,,;27.28.29.Place the differential housing complete withcrown wheel and bearings in the pinionhousing.Fit the bearing caps and bolts. Do not fullytighten the bolts.Fit the bearing adjusting nuts and adjust toobtain zero end-float.Fit the pinion head bearing track and theoriginal shim to the pinion housing usingservice tools R0262757A and R0262757-1. Ifthe original shim was damaged or mislaid usea new shim of at least 1.27 mm (0.050 in)thickness._..’Ii\q-q-+-7--i.ai-77RR2666Evi-3t4 REVISED: DEC. 88‘.


;;g; 1989 REAR AXLE & FINAL DRIVE,’35. Fit the pinion outer bearing track to the pinionhousing with service tools R0262757A andR0262757-2.37. Enter the pinion into its location in the pinionhousing. Do not fit the shims for bearingpre-load at this stage.38. Fit the outer bearing and spacer.39. Fit the driving flange, washer and nut.: ‘. .:36. Fit the pinion head bearing to the pinion usingservice tool 18G47-6.40. Do not fit the oil seal at this stage.41. Tighten the pinion flange nut slowly until theforce required to rotate the pinion is 23 to40.25 kgf cm (20 to 35 in lb) if new beatingsare fitted. This will pre-load the bearings inorder to check the pinion height dimension.NOTE: If using original bearings, which arebedded in, the pre-load figure is 11.5 to 17.25kgf cm (10 to 15 in lb)Drive pinion markings42. The markings on the end face adjacent to theserial number are of no significance duringservicing.REVISED: DEC. 88 5


‘.’ ,’. . .: i :,REAR AXLE & FINAL DRIVE1989 KANCltROVER43. The figure marked on the end face oppositeto the serial number indicates, in thousandthsof an inch, the deviation from nominalrequired to correctly set the pinion. A pinionmarked plus t +) must be set below nominal, aminus (-) pinion must be set above nominal.An unmarked pinion must be set at nominal.PINION HEIGHT SHIMSr-PART No. INCH MM549230 ,038 0.97549232 ,040 1.02549234 ,042 1.07549236 ,044 1.12549238 .046 1.17549240 ,048 1.22549242 ,050 1.27549244 .052 1.32549246 ,054 1.37549248 .O% 1.42549250 .058 1.47549252 .060 1.52ST517M44. The nominal setting dimension is representedby the setting gauge block 18C191-4 which isreferenced from the pinion end face to thebottom radius of the differential bearing bore.Drive pinion adjustment48. Position the dial gauge centrally on the pinionend face with the trace pin registering on thelowest point on one differential bearing bore.Note the dial gauge deviation from the zeroedsetting.45. Ensure that the pinion end face is free ofraised burrs around the etched markings.46. Remove the keep disc from the magnetizedbase of dial gauge tool 18Gl91.47. Place the dial gauge and setting block on a flatsurface and zero the dial gauge trace pin onthe setting block. Use of a surface plate isrecommended.NOTE: The setting block has three settingheights as follows.Use only the 39.50mm setting mark for thisdifferential.49. Repeat on the other bearing bore. Addtogether the readings then halve the sum toobtain the mean reading. Note whether thetrace pin has moved up or down from thezeroed setting.a. Where the trace pin has moved down, theamount is equivalent to the thickness of shimsthat must be removed from under the pinioninner track to bring the pinion down to thenominal position.,I/ST518M6 REVISED: DEC. 88


REAR AXLE & FINAL DRIVE r51l:’b. Where the trace pin has moved up, theamount is equivalent to the additionalthickness of shims required to bring the pinionup to the nominal position.‘. .,.INCH.OOl.002.003.004.005.006.007,008,009.OlOMM= .025= .05= .075= .I0= .125= .I5= ,175= .20= .225= .25NOTE: DIAL INDICATOR IS METRIC! Conversionmust be made to SAE (INCH) UNITS whenperforming measurements and selecting shims.50. Before adjusting the shim thickness, check thepinion face marking and if it has a plus (+)figure, subtract that amount in thousandths ofan inch from the shim thickness figureobtained in the previous item.51. Alternatively, if the pinion has a minus (-)figure, add the amount to the shim thicknessfigure. Adjust the shim thickness under thepinion head bearing track as necessary.52. Recheck the pinion height setting. If thesetting is correct, the mean reading on the dialgauge will agree with the figure marked on thepinion end face. For example, with an endface marking of +3, the dial gauge readingshould indicate that the pinion is + 0.003 in.Bearing pre-load adjustment53. Remove the pinion flange, pinion, outerbearing and spacer.54. Slide new shims, of the same thickness as theoriginals (bearing pre-load) into position onthe pinion shaft. If the original shim wasdamaged or mislaid use a new shim of at least4.06 mm (0.160 in) thickness.55. Enter the pinion in its location in the pinionhousing 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.58. Tighten the pinion flange nut to the specifiedtorque (see section 06-Torque values). Theforce required to rotate the pinion shaftshould be within 23 to 40.25 kgf cm (20 to 35in lb) using new bearings, when initial inertiahas been overcome. Change the bearingpre-load shim as necessary to obtain thisrequirement. A thicker shim will reducepre-load; a thinner shim will increase pre-load.NOTE: If using original bearings, which arebedded in, the pre-load figure is 11.5 to 17.25kgf cm (10 to 15 in lb)59. Remove the pinion flange.PINION PRELOAD SHIMSPART No. INCH MMFRC1193 .060 I.52FRCl195 ,062 1.57FRC1197 ,064 I.63FRC1199 .066 1.68FRCI 201 .068 I.73FRCl203 .070 1.78539718 .072 1.83539720 .074 1.88539722 .076 1.93539724 ,080 2.03:. .Fitting Pinion Oil SealCAUTION: Before fitting the new seal to thedifferential, examine the seal to ensure that it isclean, undamaged and that the garter spring isproperly located. A small scratch on the seal lipscould impair its efficiency.IREVISED: JULY 88 7


REAR AXLE & FINAL DRIVE1987 lcANGEROVER60. Coat the outer diameter of the new seal widthwith an all purpose grease and fit the seal, lipside leading squarely on the pinion nosehousing and drive the seal into position flushwith the end face of the housing using sealreplacing tool LST106.64. Fit the bearing adjusting nuts.ST522MRR968M65. Push the crown wheel into mesh with thepinion, loosening the left hand bearingadjuster nut, using service tool 530105.66. Tighten the right hand nut until crownwheel/pinion backlash is just removed.61. Lightly lubricate the seal lips with arecommended oil. Fit the distance piece andflange and secure with washer and nut.Tighten the nut to the specified torque and fita new cotter pin (see section 06-Torquevalues)..’ ,IJRR96sM67. Tighten the left hand nut slowly until itcontacts the bearing. Continue turning the lefthand nut until a backlash of 0.10 to 0.17 mm(0 004 to 0.007 in) is achieved. DO NOTslacken the right hand nut at any time,othmwse the bearing preload will be affected.:CROWN WHEEL/PINION BACKIASHADJUSTMENT62. Place the differential housing in the pinionhousing.63. Fit the bearing caps and bolts. Do not fullytighten the bolts.CAUTION should also be taken when performingBacklash Setup i.e. convert metric readings toinches.. -*.i8 REVISED: JULY 88


:.REAR AXLE & FINAL DRIVE68. Fit the locking fingers and roll pins. Ifnecessary, tighten the adjustment nuts slightlyto align the locking finger with a slot.69. Evenly tighten the bearing cap bolts to thespecified torque (see section 06-Torquevalues).70. Recheck crown wheel/pinion backlash.71. Lubricate the bearings and gears.DATAPinion bearing pre-load:(new bearings) .......................................... 23 to 40.25 kgf cm (20 to 35 in lb)(bearings bedded in) ................................. 11.5 to 17.25 kgf cm (IO to 15 in lb)Crown wheel run-out ...........................................0.10 mm (0.004 in)Crown wheel/pinion backlash ............ I ,................. 0.10 to 0.17 mm (0.004 to 0.007 in)REAR DISCSRemove and refitRemoving1. Remove the rear hub assembly.2. Remove the rear disc fixing bolts.3. Tap off the disc from the rear hub.Refitting7. Fit the rear hub assembly.Disc ReclamationCheck the disc thickness marked on the discboss-this dimension may be reduced to a minimumthickness of 13 mm (0.510 in) front and 12 mm(0.460 in) rear, by machining an equal amount offeach face.REMOVE AND OVERHAUL REAR HUBS(. :..>.4. Locate the disc onto the rear hub. Service tools:5. Fit the disc fixing bolts. See Section 06 fortightening torques.Oil seal replacer -LST550-56. Using a dial indicator, check the total disc run Drift for above tool -MS550 or 186134out, this must not exceed 0.15 mm (0.006 in). Hub nut wrench -606435If necessary reposition the disc.1 3Remove1. Jack-up the vehicle, lower on to axle standsand remove the road wheels.2. Release the brake hose from the axle, casingclips and remove the brake caliper retainingbolts and secure the assembly to one side.Tal e care not to kink the brake hose.Remove the five bolts securing the axle shaftto the hub and withdraw the shaft.RR984MREVISED: MARCH 90 9,:;


REAR AXLE & FINAL DRIVE1987 kANbcROVER4. Bend back the lock tab and remove the outernut using box wrench 606435 and remove -remove the lock washer. Likewise remove theinner nut.5. Remove the seal track spacer.6. Withdraw the hub complete with bearing oilseals and brake disc.7. Remove the inner and outer oil seals.8. Remove the inner and outer bearing cones(races).9. Drive-out the inner and outer bearing cups.1 I. Examine the stub axle and in particular checkthat the inner seal track is smooth and freefrom blemishes.12. If necessary remove the six retaining bolts andremove the stub axle complete with themudshield and joint washer.::10. Degrease and examine the hub and brake discand if necessary replace both or whicheverpart is unserviceable. The disc is attached tothe hub with five bolts. Mark the relationshipof the hub to the disc if the original parts areto be re-assembled.Assemble13. Using a new joint washer fit the stub axle andmud shield. Coat the threads of the retainingbolts with Loctite 270 and tighten evenly tothe correct torque (see section OC-Torquevalues).14. Fit the new inner and outer bearing cups tothe hub, using a suitable drift or commercial --bearing race driving tool.10 REVISED: MARCH 90


REAR AXLE & FINAL DRIVE [ii 1.,15. Fit the new inner bearing cone and pack withone of the recommended hub greases.Fitting new oil seal-inner16. Clean the hub oil seal housing and ensure thatthe seal locating surface is smooth and thechamfer on the leading edge is also smoothand free from burrs.17. Examine the new seal and ensure that it isclean and undamaged and that the garterspring is properly located. Even a small scratchon the seal lip could impair its efficiency.18. Although the new seal is already pre-greasedby the manufacturer, apply one of therecommended hub bearing greases to theoutside diameter of the seal before fitting,taking care not to damage the lip.19. Place the seal, lip side leading, squarely on thehub and using the 76 mm end of seal replacertool LSTSSO-5and drift 550 or 18C134, drivethe seal into position, flush with the end faceof the hub.Fitting outer oil seal20. Fit the new outer bearing cone and pack withone of the recommended hub greases. Carryout instructions 16 to 18.21. Place the seal, lip side leading, squarely on thehub and using the 72 mm end of seal replacertool LSTSSO-5and drift 550 or l8Gl34, drivethe seal into position to the depth determinedby the tool.22. Coat the lips of both seals with one of therecommended greases. This is important sincea dry seal can be destroyed during the firstfew revolutions of the hub.Fitting hub to stub axle23.24.25.26.Select a new seal track spacer and check thatthe outer diameter is smooth and free fromblemishes and that there are no burrs on thechamfered leading edge.Taking care not to damage the seal lips fit thehub assembly to the stub axle. Do not allowthe weight of the hub to rest even temporarilyon the outer seal otherwise damage anddistortion could occur. Therefore hold the hubclear of the stub axle until the seal trackspacer is fitted.Carefully fit the seal track spacer, seal lipleading.NOTE: Instruction 26 is applicable to hubsthat have been fitted with new componentsthroughout. If original components arebeing refitted instruction 27 must befollowed using the adjustment nut toachieve the required end-float.Fit the hub inner nut and using wrench 606435tighten the adjusting nut while slowlyrevolving the hub until all end-float isremoved, then back-off the nut approximatelyhalf a turn and retighten the nut to 13-15 in lbwhich will automatically allow for compressionof the rubber on thP new seal track spacergiving the required hub end-float of 0.013 to0.10 mm (0.0005 to 0.004 in).Continued.REVISED: APR. 88 ‘11:,.


-t 51 REAR AXLE & FINAL DRIVE1987 KANClcROVER27. If the rubber on the seal track spacer haspreviously been compresssed the hubend-float can be checked by mounting a dialindicator and bracket on the hub so that thetrace pin rests in a preloaded condition on thenut. Rotate the hub to settle the bearings andcheck the end-float by pushing and pulling thehub. End-float must fall within the limits givenin the previous instruction.28. Fit a new lock washer and locknut. Restrainingthe inner adjustment nut, tighten the outerlock nut to 70 to 80 ft lb (95 to 108 Nm).29. If original components have been refittedrotate the hub several trmes to settle thebearings then recheck the end-float, refer toprevious note and instruction 27.30”’RR709M33. Fit the road wheels, jack-up the vehicle,remove the axle stands, lower the vehicle tothe ground and tighten the road wheel nutsevenly to the correct torque.30. Bend one segment of the lock washer overthe adjusting nut and another, diametricallyopposite, over the locknut taking care not todamage the outer seal.31. Using a new joint washer, fit the hub driving’shaft and evenly tighten the retaining bolts tothe correct torque (see section 06-Torquevalues).32. Fit the brake caliper and secure with theretaining bolts and tighten to the correcttorque (see section 06-Torque values). Securethe brake pipes to the axle casing.12 REVISED: APR. 88


’ :i.:.,REAR AXLE & FINAL DRIVE1.:xKEY TO REAR HUB COMPONENTS..; :,: .I,:,,_I,*.A’.....- 1. Rear axle shaft 11. Inner bearing cup2. joint washer 12. Inner bearing cone3. locknut 13. Inner oil seal4. Lock washer14. Mudshield5. Adjusting nut 15. Stub axle6. Seal track spacer 16. Stub axle joint washer7. Outer oil seal 17. Brake disc8. Outer bearing cone9. Outer bearing cup10. HubvREVISED: APR. 8813.,... .,j


REAR AXLE & FINAL DRIVE1990 ;;g$;REAR HUB ASSEMBLY ON VEHICLES FIT-TED WITHANTI-LOCK BRAKES (ABS)REMOVE, OVERHAUL AND REFITService tools:Hub oil seal replacer LST 137.Drift 18C 134.Dial gauge bracket RO 530106.Remove1. Slacken the rear wheel nuts, jack up thevehicle, lower onto axle stands and removethe road wheel.2. Release the brake pipe from the axle, casingclips and remove the brake caliper retainingbolts then secure the assembly to one side.WARNING: Take care not to kink the brakepipe.3. Lever off the dust cap.4. Remove the circlip from the rear axle shaft.5. Remove the five bolts and withdraw thedriving member and joint washer.6. Bend back the lock washer tab.7. Remove the locknut and tab washer.8. Remove the hub adjusting nut.9. Remove the keyed washer.10. Withdraw the hub and brake disc assemblycomplete with bearings.11, Remove the outer bearing.12. Remove the five nyloc nuts and withdraw thesensor ring.13. Mark, for reassembly, the relationship betweenthe hub and brake disc, if original hub is to berefitted.14. Remove the five bolts and separate the hubfrom the brake disc.WARNING: A maximum of two road wheelretaining studs can be renewed. Shouldmore studs be unserviceable a new hubwith studs must be obtained.15. Drift out the grease seal and inner bearingfrom the hub and discard the seal.16. Drift out the inner and outer bearing tracks.KEY TO REAR HUB COMPONENTS1. Dust cap.2. Circlip.3. Sensor ring retaining nut.4. Drive member.5. Drive member joint washer.6. Drive member retaining bolt (five off).7. Lock nut.8. Lock washer.9. Hub adjusting nut.10. Keyed washer.11. Outer bearing.12. Hub.13. Inner bearing.14. Grease seal.15. Brake disc.16. Disc retaining bolt (five off).17. Sensor ring.,:RR2766M ‘6‘.‘.1 4ADDITION: SEPT. 89.‘) :


R”^o”;; 1990REAR AXLE & FINAL DRIVERefit 20.17. Clean and degrease the hub and drift in theinner and outer bearing tracks.21.22.23.24.25.26.27.Assemble the brake disc to the hub, lining upto the marks made during dismantling.Applying Loctite 270, fit and tighten the fiveretaining bolts to the correct torque.If necessary renew any sensor ring studsapplying Loctite 270 where the stud screwsinto the sensor ring. Fit the sensor ring usingnew nyloc nuts, ensuring it is correctly fittedto avoid tooth run out.Grease as in instruction 18 and fit the outerbearing to the hub.Clean the stub axle and rear axle shaft andretract the ABS sensor slightly from sensorsleeve.Fit the hub assembly to the stub axle.Fit the keyed washer.Fit the hub adjusting nut and tighten by handwhilst rotating the hub until all end-play istaken up.Mount a dial gauge using bracket RO 530106and rest the stylus in a loaded condition onthe adjusting nut.,_ .’18. Pack the hub inner bearing with arecommended grease and fit to the hub.19. With the lip side leading fit a new seal to thehub using special tool LST 137 seal replacerand drift 18G 134. Drive in the seal so that itis flush with the rear face of the hub. Applygrease between the seal lips.RR2772M RO 530106.’_...,;’ ‘,LST137 I I28 Gcken off the adjusting nut until a end-play(110 013 to 0,05 mm (0.0005 to 0.002 in) is(~l~ralned.2’1 I II a new keyed lock tab washer.(11I II and tighten the hub adjusting nut andI(‘( heel, the end-play before bending the locktdb over.31 Fir a new joint washer to the driving memberand frt the member to the hub and securewith the five bolts tightening evenly to thecorrect torque.;:‘-, ::,RR2770M. . 4.I,.,’. . .ADDITION: SEPT. 89 15


REAR AXLE & FINAL DRIVE1990 R”d;;i32. Fit the circlip to the rear axle shaft, ensuringthat it locates in the groove.33. Fit the dust cap.34. Fit the brake caliper and tighten the two bolts!o the correct torque. Secure the brake pipesto the axle casing.35. Set the ABS brake sensor. Push the sensorthrough the bush until it touches the sensorring. The sensor sets to its correct positionwhen the hub is rotated.36. Fit the road wheel, remove the axle stands andfinally tighten the road wheel nuts.37. Operate the footbrake several times to locatethe brake pads before taking the vehicle onthe road.REAR STUB AXLE ON VEHICLES FlITED WITH ABSSpecial tools:Oil seal replacer LST 138.Drift 18G 134.KEY TO STUB AXLE COMPONENTS1. Rear axle shaft.2. Stub axle to axle casing bolt.3. Mudshield.4. Stub axle.5. Stub axle joint washer.6. Axle case.7. Sensor bush sleeve.REMOVE, OVERHAUL AND REFITRemove rear stub axle, axle shaft1. Remove the hub complete as described in theoperation to overhaul the hub assemblyinstructions 1 to 10.2. Remove the six bolts retaining the stub axle tothe axle casing.3. Remove the mud shield.4. Remove the stub axle and joint washer.5. Pull-OUI the rear axle shaft from the axlecasing.Refit6. Using a new joint washer fit, the stub axle andmudshield with the retaining bolts, to the axlecasing tightening evenly to the correct torque.7. Carefully fit the rear axle shaft to avoiddamaging the stub axle seal.8. Refit the hub assembly complete as describedin the operation to refit the hub assemblyinstructions 23 to 37.Renew rear stub axle oil seal1. Remove and discard the oil seal. Lubricate theseal and lip with EP90 oil and using specialtool LST 138 fit a new oil seal lipside trailingso that the seal is flush with the rear face ofthe stub axle.RR2759Mkd..-.,: > ;. . . . .;’ ‘\)ADDITION: SEPT. 89


REAR AXLE & FINAL DRIVEREAR DISCS ON VEHICLES FllTED WITH ABSREMOVE, REFIT AND RECLAIMRemoving1. Remove the rear hub assembly.2. Remove the five nyloc nuts.3. Remove the sensor ring.4. Remove the five hub to disc retaining bolts.5. Tap off the disc from the hub.Refitting6. Locate the disc onto the hub.7. Apply loctite 270 and fit the hub to discretaining bolts. Tighten to the correct torque.8. Using new nyloc nuts fit the sensor ring.9. Using a dial indicator, check the total discrunout, this must not exceed 0,15 mm (0.006in). If necessary reposition the disc.10. Fit the hub assembly.Disc ReclamationCheck the disc thickness. This dimension maybe reduced to a minimum thickness of 12 mm(0.460 in). Equal amounts must be machinedoff both sides of the disc.; ‘--i..‘. :._.ADDITION: SEPT. 89 17


oFf; 1987FRONT AXLE & FINAL DRIVEFRONT AXLE ASSEMBLYRemove and refitRemoving1536 \ ll& !. E‘.: :WARNING: The removal of the axle from thevehicle will require the assistance of two furtherpersonnel to steady the axle when lowering fromthe vehicle.Jack up the front of the vehicle and supportthe chassis frame.Remove the front road wheels.Support the axle weight with a suitablehydraulic jack.Remove the nuts securing the radius arms tothe chassis frame side members.RR983MiRR742M11. Remove the nuts and washers securing theshock absorbers to the axle.12. Using a suitable extractor disconnect the draglink from the swivel pin housing arm.13. Remove the two nuts and bolts securing thepanhard rod to the axle bracket and lift therod clear of the axle.14. Mark the differential and drive shaft flangeswith identification marks to aid re-assembly.Remove the four nuts and bolts, tie the driveshaft to one side.15. Carefully lower the axle assembly and removethe road springs.16. Withdraw the axle assembly.Refitting: ‘_’.:.y.5.6.7.8.9.IO.Disconnect the steering damper at the tie rodand using a suitable extractor remove the tierod ends from the swivel pin housing arm.Remove the four nuts and bolts securing theradius arms to the axle bracket.Lower the radius arms and withdraw themfrom the chassis side members.Remove the two bolts from the top of theswivel pin housings securing the brake hosebrackets. Remove the brackets and refit thebolts to prevent oil leakage.Disconnect the brake pad wear electricalmulti-plug at the rear of the caliper (whereapplicable).Remove the bolts securing the brake calipersand tie the calipers to one side.17.18.19.Position the axle under the vehicle, supportingthe left hand side of the axle.Reverse the removal instructions.Tighten the drive shaft to differential bolts tothe specified torque (see section 06-Torquevalues).Tighten the panhard rod to axle bracket to the20.specified torque (see section 06-Torquevalues).21. Tighten the drag link to hub arm to thespecified torque (see section OC-Torquevalues).22. Tighten the upper swivel pin retaining bolts tothe specified torque (see section 06-Torquevalues).23. Tighten the radius arms to axle bolts to thespecified torque (see section 06-Torquevalues).REVISED: JULY 88


,:,.:,.24. Tighten the radius arms to chassis side FRONT DISCSmember nuts to the specified torque (seesection 06-Torque values).Remove and refit25. Tighten the track rod end to the specifiedtorque and fit a NEW cotter pin (see section Removing06-Torque values).FRONT DIFFERENTIAL-OVERHAULThe front and rear differentials fitted to Range Roverare the same type. When overhauling the frontdifferential refer to the rear differential overhaulprocedure in Section 51 of this manual.1. Remove the front hub assembly.2. Remove the front disc fixing bolts.3. Tap the disc off the front hub.1 3Refitting4. Locate the disc onro the front hub.5. Fit the disc fixing bolts. See Section 06 fortightening torques.6. Using a dial indicator, check the total discrun-out, this must not exceed 0.15 mm (0.006in). If necessary, reposition the disc.7. Fit the front hub assembly..i.:,(.‘.. ., 2,.“..,:’,...I. .;‘;REVISED: JULY 88


IPO;;; 1987FRONT AXLE & FINAL DRIVE l-l54REMOVE AND OVERHAUL FRONT HUBService tools:Oil seal replacer ................................................. LSTSSO-5Drift for above tool ............................................. MS550 or 18Gl34Hub nut wrench .................................................. 606435KEY TO FRONT HUB COMPONENTS1.2.3.4.5.6.7.8.9.10.11.12.Hub driving shaftGasketLocknutLock washerAdjusting nutSeal track spacerOuter oil seal13. Inner oil seal14. Mudshield15. Stub axle16. Stub axle joint washer17. Brake disc..-I’; ,’‘_Remove1. lack-up the vehicle, lower onto axle standsand remove the road wheels.2. Remove the swivel housing top bolt to releasethe brake hose bracket.3. Remove the brake caliper retaining bolts andrelease the assembly from the brake disc andsecure to one side.4. Remove the five bolts retaining the hubdriving shaft and withdraw the shaft from thehub.5. Bend back the lock-tab and remove the outernut using wrench 606435 and remove the lockwasher. Similarly, remove the inner nut.6. Remove the seal track spacer.7. Withdraw the hub complete with bearings, oilseals and brake disc.8. Remove the inner and outer oil seals.9. Remove the inner and outer bearing cones..iREVISED: FEB. 87 3


54 FRONT AXLE & FINAL DRIVE1987 KANCIEROVER10. Drive out the inner and outer bearing cups.13. If necessary remove the retaining bolts andwithdraw the stub axle. Complete with themudshield and joint washer...-,’Assemble14. Using a new joint washer fit the stub axle andmudshield. Coat the threads of the retainingbolts with Loctite 270 and tighten evenly tothe specified torque (see section 06-Torquevalues).15. Fit the new inner and outer bearing cups tothe hub, use a suitable brass drift orcommercral race driver to prevent damage tothe bearing cups.,I11. Degrease and examine the hub and brake discand fit new components where necessary. Thebrake disc is attached to the hub by five bolts.Mark relation of hub to disc as necessaryRR070M .-\.16. Fit the new inner bearing cone and pack withone of the recommended i xubgreases.Fitting new oil seal-inner1’ 6. Clean and examine the stub axle and inparticular check that the inner seal trackdiameter is smooth and free from blemishes.17. Clean the hub oil seal housing and ensure thatthe seal locating surface is smooth and thechamfer on the leading edge is also smoothand free from burrs.18. Examine the new seal and ensure that it isclean and undamaged and that the garterspring is properly located. Even a small scratchon the seal lip could impair its efficiency.4 REVISED: FEB. 87


R”%; 1987FRONT AXLE & FINAL DRIVE [!$i 1; ;19.20.Although the new seal is already pre-greasedby the manufacturer, apply one of therecommended hub bearing greases to theoutside diameter of the seal before fitting.Place the seal, lip side leading, squarely on thehub and using the 76 mm end of seal replacertool LST550-5 and drift 550 or 18Cl34, drivethe seal into position flush with the end faceof the hub.27.Carefully fit the seal track spacer, chamferedside leading.NOTE: Instruction 28 is applicable to hubsthat have been fitted with new componentsthroughout. If original components arebeing refitted instruction 29 must befollowed using the adjustment nut toachieve the required end-float.28.29.Fit the hub inner nut and using wrench 606435tighten the adjusting nut while slowlyrevolving the hub until all end-float is removedmen back-off the nut approximately half a turnand retighten the nut to 13-15 in lb which willautomatically allow for compression of therubber on the new seal track spacer giving therequired hub end-float of 0.013 to 0.10 mm(0.0005 to 0.004 in ).If the rubber on the seal track spacer ‘haspreviously been compressed the hub end-floatcan be checked by mouting a dial indicatorand bracket on the hub so that the trace pinrests in a preloaded condition on the nut.Rotate the hub to settle the bearings andcheck the end-float by pushing and pulling thehub. End-float must fall within the limits givenin the previous instruction.Fitting outer oil seal.-21. Fit the new outer bearing cone and pack withone of the recommended hub greases.22. Carry out instructions 17 to 19.23. Place the seal, lip side leading, squarely on thehub and using the 72 mm end of seal replacertool LST550-5 and drift 550 or 186134, drivethe seal into position to the depth determinedby the tool.24. Coat the lips of both seals with one of therecommended greases. This is important sincea dry seal can be destroyed during the firstfew revolutions of the hub.Fitting hub to stub axle,. ’ .25. Select a new seal track spacer and check thatthe outer diameter is smooth and free fromblemishes and that there are no burrs on thechamfered leading edge.26. Taking care not to damage the seal lips fit thehub assembly to the stub axle. Do not allowthe weight of the hub to rest even temporarilyon the outer seal otherwise damage anddistortion could occur. Therefore hold the hubclear of the stub axle until the seal trackspacer is fitted.Continued-’REVISED: APR. 88 5‘.:


1987 KANbtROVER.’: ;’30. Fit a new lock washer and iocknut. Restrainingthe inner adjustment nut, tighten the outerlock nut to 70 to 80 ft lb (95 to 108 Nm).31. If original components have been refittedrotate the hub several times to settle thebearings then recheck the end-float, refer toprevious instruction 29.32. Bend one segment of the lock washer overthe adjusting nut and another, diametricallyopposite, over the locknut.32‘\‘\OVERHAUL STUB AXLE, AXLE SHAFT, CONSTANTVELOCITY JOINT AND SWIVEL PIN ASSEMBLYRemoving hub assembly, stub axle, constantvelocity joint and axle shaft.Remove the hub complete as described in thehub assembly overhaul operation instructions1 to 7.Drain the swivel pin housing and refit plug.Remove the six bolts retaining the stub axle tothe swivel pin housing.Remove the mud shield, stub axle and jointwasher.Remove the brake disc shield secured by onenut and bolt at the bottom front, and onebolt, behind the shield, in the swivel pinhousing.II31AR976846. Disconnect the tie-rod end ball joint from theswivel pin housing.7. Disconnect the drag-link ball joint.‘.-.:‘!33. Using a new gasket, fit the hub driving shaftand evenly tighten the retaining bolts to thespecified torque (see section 06-Torquevalues).34. Fit the brake caliper and secure with theretaining bolts and tighten to the specifiedtorque (see section 06-Torque vaiues).35. Fit the swivel housing top bolt and brake hosebracket and tighten to the specified torque(see section 06-Torque values).36. Fit the road wheels, jack-up the vehicle,remove the axle stands, lower the vehicle tothe ground and tighten the road wheel nutsevenly to the specified torque (see section06-Torque values).I‘.1..’6REVISED: APR. 88.’


:,:.Foe; 1987FRONT AXLE & FINAL DRIVE:8. Remove the constant velocity joint from theaxle shaft.Dismantling the constant velocity joint11.12.Mark -the relative positions of the constantvelocity joint, inner and outer race and thecage to ensure correct re-assembly.Tilt and swivel the cage and inner race toremove the ball bearings,‘.’‘.:.‘.,:,..RR207SM.’,..’9. Remove the spacer from the axle shaft andthen the axle shaft from the axle tube.Continued10. Remove the phosphor bronze bush from theaxle shaft.RR2076M \REVISED: JULY 88


FRONT AXLE & FINAL DRIVE1987 KANbtROVEROverhaul of stub axle18.19.20.Remove the phosphor bronze bush using asuitable hammer and drift.Clean and examine the stub axle. In particularcheck that the inner seal track diameter issmooth and free from blemishes.Using a suitable block, press or drive-in a newbush up to the shoulder of the stub axle.. .Removing the swivel pin housing assembly21.Remove the seven bolts securing the swivelpin housing oil seal, retaining plate and jointwasher. Release the assembly from the swivelpin housing.NOTE: While the joint washer can beremoved at this stage, the oil seal andretaining plate must remain until the swivelbearing housing is removed.RR207BM13. Swivel the cage into line with the axis of thejoint until the two opposite windows coincidewith the two lands of the joint housing.14. Withdraw the cage.15. Turn the inner track at right angles to the cagewith two of the lands opposite the cageopenings, and withdraw the inner race.16. Examine all components for general conditionand examine the inner and outer track, cageballs and bearing surfaces of the constantvelocity joint for damage and excessive wear.Maximum acceptable end-float on theassembled joint 0.64mm (0.025 in).17. To assemble the constant velocity joint reversethe dismantling instructions and lubricate witha recommended oil, ensuring that the innerand outer race marks are aligned duringassembly.22.23.24.25.26.27.28.Remove the two bolts, retaining the brake discshield bracket, and lower swivel pin to thehousing.Remove the brake disc shield bracket.Tapping the small protruding lug remove thelower swivel pin and joint washer.Remove the two bolts retaining the brakehose bracket and top swivel pin.Remove the brake hose bracket, top swivel pinand shims.Remove the swivel pin housing while retrievingthe lower and upper tapered roller bearings.If the swivel pin housing is to be replaced,remove the drain and level plugs andlock-stop bolt and nut.,_. . .. ,:.8 REVISED: JULY 88:.‘.: .;,


;;%; 1987FRONT AXLE & FINAL DRIVE 54 r - lOverhaul of swivel bearing housing29. Using a suitable drift ease the lower bearingtrack out of the swivel bearing housing.NOTE: Use the upper bearing opening forthe drift to gain access to the lower bearingtrack.630.31.32.33.Remove the seven bolts retaining the swivelbearing housing to the axle case.Pry out the oil seal from the back of thehousing also remove the joint washer anddiscard both.Bolt the swivel bearing housing onto the axlecase with the upper bearing track located atthe bottom.Drive out the top bearing track from theswivel bearing housing.34. Remove the bolts from the housing.35. If worn, pitted or damaged, fit a new housing.36. Using a suitable toolseat the upper and lowerbearing tracks into the swivel bearing housing.37.NOTE: Use the lower bearing opening forthe drift to gain access to the upper bearingtrack.NOTE: Ensure the bearing tracks are fittedsquare or damage could occur.With the seal lips trailing press the axle shaftoil seal into the rear of the housing, alsogrease the lips.RRBBOMIr11KEY TO SWIVEL ASSEMBLY1. Swivel pin housing2. Top swivel pin and brake hose bracket3. Upper and lower swivel pin bearings4. Shim5. Swivel pin housing-oil seal plate and washer6. Oil seal7. Joint washer8. Swivel bearing housing9. joint washer10. Lower swivel pin11. Brake disc mudshield bracket12. Swivel bearing housing inner oil sealReassembling the swivel pin housing assembly38.39.40.41.42.Coat the swivel bearing housing to axle casing.bolts with Loctite 270.Coat both sides of the joint washer with asealing compound and place in position onthe swivel bearing housing to axle mating face.Place the swivel pin housing cover plate jointwasher and oil seal over the axle flange readyfor assembly.Fit and secure the swivel bearing housing tothe axle flange with the seven bolts tighteningevenly to the specified torque (see section06-Torque values).Grease and fit the upper and lower swivel pintaper roller bearings to the swivel bearinghousing.Continuedi.’. . _-.:,,t+\.!’ --.- ,‘(/ .’REVISED: JULY 88 9 , .,’. .


FRONT AXLE & FINAL DRIVE43. Place the swivel pin housing in position overthe swivel bearing housing.44. Coat a joint washer on both sides with asealing compound and place in position onthe lower swivel pin.45. Fit the lower swivel pin with the lug outboardto the swivel pin housing. (DO NOT tightenthe bolts at this stage).46. Fit the top swivel pin with existing shims andbrake hose bracket onto the swivel pinhousing, securing with the two bolts andlocking washers. (DO NOT tighten the boltsat this stage).4i. Coat the threads of the two lower swivel pmbolts with Loctite 270.48. Fit the brake disc shield bracket and securewith the two bolts to* the specified torque (seeSection 06) and bend over the lock tabs of themudshield bracket.49. Tighten the top swivel pin bolts to thespecified torque (see Section 06.Torquevalues).1987 nANb=ROVER51. Liberally apply (but do not pack) 2.5 to 4.Og of .-!recommended grease between the lips of theswivel oil seal.52. Secure the oil seal, joint washer and coverplate with the seven bolts and spring washersto the specified torque (see Section 06-Torquevalues).53. Fit the tie-rod and drag link and secure withnew cotter pins, where applicable. Tighten tothe specified tourque. (See Section 06 TorqueValues)54. Fit the brake disc shield.55. Loosely fit the lock stop bolt and nut for lateradjustment.Constant velocity, stub axle and axle shaftreassembly56. Fit a new phosphor bronze bush onto the axleshaft. 157. Place axle shaft into axle tube, ensuring thesplines are engaged push the shaft home.:.‘.!CAUTION: When inserting the axle shaft careshould be taken not to damage the oil seal.58.59.60.61.Fit the constant velocity bearing journal intothe phosphor bronze bush at the rear of thestub axle.Fit the spacer onto the axle shaft.Place the joint washer in position on theswivel pin housing to stub axle mating surface.Fit the stub axle with the machined flat on thesplines in the 12 o’clock position, ensuringthat the constant velocity bearing journalengages fully into the phosphor bronze bush.; ,’RR982M - 1CAUTION: Damage to this bush can occur if thisprecaution is not observed..,,i: ”.,‘..50. To check the top swivel pin pre-load, attach aspring balance to the track-rod and ball jointbore and pull the balance to determine theeffort required to turn the swivel pin housing.The resistance, once the initial inertia has beenovercome, should be 1.16 to 1.46 kg (2.6 to3.2 lb). If necessary, adjust by removing oradding shims to the top swivel pin as required.When the correct setting has been achievedundo the bolts, coat the threads with Loctite270 and retighten the bolts to the specifiedtorque (see Section 06-Torque values), andbend over the tabs of the locking washer.62. Place the mudshield onto the stub axle and>ecurc to the swivel pin housing with the sixt)ol~~ using Loctite 270. Evenly tighten to the51~~Itled torque (see Section OC-Torque1dlIW\ j63 10 ’ 1 )mplete the reassembly see instructions: I 1111t1covering front hub overhaul.NOTE: New hub seals should be used onreassembly..i64. CherL that the swivel pin housing drain plug istlghrl\ tltted and remove the filler/level plug.65. lnlect approximately 0.35 litres (0.6 pints) ofrecommended oil or until the oil reaches thefiller level hole. Fit and tighten the plug andwipe away any surplus oil.10 REVISED: JULY 8866. Set the steering lock-stop bolts to provide a : .“;minimum clearance of 20 mm (0.787 in) . . .’between the tyre wall and radius arm. Tightenthe locknut.::, :; ::_:


R”;g 1990FRONT AXLE & FINAL DRIVE hii1.. .:.- 1.1.,: .,:.t:FRONT HUB ASSEMBLY ON VEHICLES FllTEDWITH ANTI-LOCK BRAKES (ABS)Service tools:Hub oil seal replacer LST 137.Drift 18C 134.Dial gauge bracket RO 530106.REMOVE, OVERHAUL AND REFITRemove1. Slacken the front wheel nuts, jack up thevehicle and lower onto axle stands andremove the road wheel.2. Remove the brake caliper. See BRAKESsection.3. Lever off the dust cap.4. Remove the circlip and drive shaft shim fromthe drive shaft.5. Remove the five bolts and withdraw thedriving member and joint washer.6.7.8.9.10.11.12.13.14.15.Bend back the lock washer tab.Remove the locknut and tab washer.Remove the hub adjusting nut.Remove the keyed washer.Withdraw the hub and brake disc assemblycomplete with bearings.Remove the outer bearing.Mark, for reassembly, the relationship betweenthe hub and brake disc, if original hub is to berefitted.Remove the five bolts and separate the hubfrom the brake disc.WARNING: A maximum of two road wheelretaining studs can be renewed. Shouldmore studs be unserviceable a new hubwith studs must be obtained.Drift out the grease seal and inner bearingfrom the hub and discard the seal.Drift out the inner and outer bearing tracks.KEY TO HUB ASSEMBLY1. Dust cap.2. Drive shaft circlip.3. Drive shaft shim.3. 4. Drive member.5. Drive member joint washer.6. D&e member retaining bolt (five off)7. Lock nut.8. Lock washer.9. Hub adjusting nut.10. Keyed washer.11. Outer bearing.12. Hub.13. Inner bearing.14. Grease seal.15. Brake disc (vented).16. Disc retaining bolt (five off).ADDITION: SEPT. 89 11‘.


1990 KANGeROVERRefit16. Clean and degrease the hub and drift in theinner and outer bearing tracks.19.20.21.22.23.24.Assemble the brake disc to the hub, lining upto the marks made during dismantling.Applying Loctite 270, fit and tighten the fiveretaining bolts to the correct torque.Grease as in instruction 17 and fit the outerbearing to the hub.Clean the stub axle and drive shaft and fit thehub assembly to the axle.Fit the keyed washer.Fit the hub adjusting nut and tighten by handwhilst rotating the hub until all end-play istaken up.Mount a dial gauge using bracket RO 530106and rest the stylus in a loaded condition onthe adjusting nut.RR2767M17.18.Pack the hub inner bearing with arecommended grease and fit to the hub.With the lip side leading fit a new seal to thehub using special tool LST 137 seal replacerand drift 18C 134. Drive in the seal so that itis flush with the rear face of the hub. Applygrease between the seal lips.18G.134LSTRR2771 M RO 53010625.26.27.28.29.Slacken off the adjusting nut until a hubend-play of 0,013 to 0,05 mm (0.0005 to0.002 in) is obtained.Fit a new keyed lock tab washer.Fit and tighten the hub adjusting nut andrecheck the end-play before bending the locktab over.Fit a new joint washer to the driving memberand fit the member to the hub and securewith the five bolts tightening evenly to thecorrect torque.Fit the original drive shaft shim and securewith a circlip..-. .,/:.12 ADDITION: SEPT. 89


FRONT AXLE & FINAL DRIVE . .30. To check the drive shaft end-play mount a dialgauge using bracket RO 530106 and rest thestylus in a loaded condition on the end of thedrive shaft.31. Fit a suitable bolt to the threaded end of thedrive shaft and using a pair of pliers move thedrive shaft back and forth noting the dialgauge reading. The end-play should bebetween 0.08 to 0,25 mm (0.003 to 0.010 in).FRONT DISCS ON VEHICLES Fill-ED WITH ABSREMOVE, REFIT AND RECLAIMRemoving1. Remove the front hub assembly.2. Remove the five hub to disc retaining bolts,3. Tap off the disc from the hub.Refitting4. Locate the disc on to the hub.5. Apply Loctite 270 and fit the hub to discretaining bolts. Tighten to the correct torque..:I,,._,-32. If the end-play requires adjustment, removethe circlip, measure the shim thickness and fitan appropriate shim to give the requiredend-play.33. Remove the bolt from the drive shaft, fit thecirclip and dust cap.34. Fit the brake caliper, see BRAKES section.35. Bleed the brake system, see ABS brake bleedprocedure.36. Fit the road wheel, remove the axle stands andfinally tighten the road wheel nuts.37. Operate the footbrake several times to locatethe brake pads before taking the vehicle onthe road.6. Using a dial indicator, check the total discrunout, this must not exceed 0,15 mm (0.006in). If necessary reposition the disc.7. Fit the hub assembly.Disc reclamationCheck the vented disc thickness. Thisdimension may be reduced to a minimumthickness of 22 mm (0.866 in).Material may be machined off the disc faces.On completion equal thicknesses of disc mustremain each side of the vent..i:_,,:‘.,.: ‘,.:::;. . ,.ADDITION: SEPT. 89 13 ‘.. .


OVERHAUL FRONT STUB AXLE,CONSTANTVELOCITY JOINT AND SWIVEL ASSEMBLY ONVEHICLES FllTED WITH ABSService tools:18C 284AAH extractor.LST 132 bearing installer.LST 133 seal installer.Remove stub axle, axle shaft and constantvelocity joint.Remove constant velocity joint from axle shaft7.8.9.Hold the axle shaft firmly in a soft jawed vice.Using a soft mallet drive the constant velocityjoint from the shaft.Remove the circlip and collar from the axleshaft./--AII,1.2.3.4.5.Remove the hub complete as described in theoperation to overhaul the hub assembly onABS fitted vehicles.Drain the swivel pin housing and refit plug.Remove the six bolts retaining the stub axle tothe swivel housing.Remove the mud shield.Remove the stub axle and joint washer.RR 2783M \1.Dismantle the constant velocity joint10. Mark the relative positions of thevelocity joint inner and outer racecage for correct reassembly.constantand the11. Tilt and swivel the cage and inner race toremove the balls.::6. Pull out the axle shaft and constant velocityjoint from the axle casing.I,. ,,. :‘.ST1 025M.i; .’1,; ‘1,.‘~.‘.;,. 1.:14 ADDITION: SEPT. 89


FRONT AXLE &FINAL DRIVE12. Swivel the cage into line with the axis of thejoint and turn it until two opposite windowscoincide with two lands of the joint housing.13. Withdraw the cage.14. Turn the inner track at right angles to the cagewith two of the lands opposite the cageopenings and withdraw the inner race.Fit constant velocity joint to axle19. Fit the collar and a new circlip.20. Engage the constant velocity joint on the axleshaft splines and using a soft mallet, drive thejoint home.IRenew stub axle,thrust ring, oil seal and bearing21. Drill and chisel off the thrust ring taking careto avoid damaging the stub axle.22. Remove the bearing and oil seal using specialtool 18C 284AAH and slide hammer. Ensurethat the fingers of the tool locate behind thebearing to drive it out. Repeat for the oil seal.18G284 AAHST1026M15 Degrease and examine all components forgeneral wear and condition.16. Examine the inner and outer track, cage ballsand bearing surfaces of the constant velocityjoint for damage and excessive wear.17 To assemble the constant velocity joint,reverse the dismantling instructions andlubricate with a recommended oil.18. Check that the end-float of the assembledjoint does not exceed 0.64 mm (0.025 in).ADDITION: SEPT. 89/REVISED:SEPT. 90 15


.FRONT AXLE & FINAL DRIVE1990 KANCltROVER,, .‘,Refit23. Lubricate the seal and lip with EP90 oil andwith the cavity side leading press in a new oilseal using special tool LST 133.LST13323---IRemove swivel pin housing.26. Remove the brake shield secured at thebottom by one nut and bolt, and midway bythe lock stop nut.27. Disconect the track-rod end ball joint from thehousing.28. Disconnect the drag-link ball joint.19. Disconnect the jump hoses from the brakejump hose bracket.30. Remove the ABS brake sensor.31. Remove the six bolts securing the oil seal andretaining plate to the swivel pin housing. Prisethe seal irom the swivel pin housing.NOTE: The oil seal and retaining platecannot be removed until the swivel pinbearing housing is removed..:..’24.RR2760MUsing special tool LST 132, fit bearing with itspart number visible when fitted, and flush withthe end face of the stub axle.32. Remove the two countersunk screws securingthe brake damper/shield bracket, and thelower swivel pin to the housing.33. Withdraw the lower swivel pin and jointwasher by tapping the small protruding lug.34. Remove the top swivel pin retaining boltscomplete with the brake jump hose bracket.35. Withdraw the top swivel pin and shims.36. Remove the swivel pin housing while retrievingthe lower taper bearing.37. If the swivel pin housing is to be renewed, thedrain, level and filler plugs and lock-stop bolt.Remove and overhaul swivel pin bearing housing38. Remove the seven bolts securing the swivelpin bearing housing to the axle case. Removethe swivel pin bearing housing.39. Remove and discard the oil seal and jointwasher.40. Drift out the lower swivel pin bearing track.41. Press out the top swivel pin bush housingassembly. Discard the thrust washer. From1991 model year, discard the thrust washersand bearing.42. If worn, pitted or damaged; renew the swivelpin bearing housing.43. Press in a new lower swivel pin bearing track.RR2761M25. Press fit a new thrust ring onto the stub axle. . .i16 ADDITION: SEPT. IJIREVISED: SEPT. 90‘.. . . . .


po;g 1990FRONT AXLE & FINAL DRIVE r54l44. Press in a new bush and bush housing. Ensurethat the relieved lip of the bush housing facestowards the rear oil seal, as shown.Check and adjust preload on bearings 1990model year57 The preload on bearings to be 0,18 to 0,23mm (0.007 to 0.009 ins), without the swivelhousing oil seal and axle fitted, and readingfrom the centre of the swivel pin. The torquerequired to turn the swivel assembly from lockto lock to be 5.1 to 7.3 Nm (45 to 65 in.lbs).Adjust by removing or adding shims to the topswivel pin.Check and adjust preload on bearings 1991model year on:45. With the seal lips trailing press the axle shaftoil seal flush into the rear of the housing.Grease the lips.46. Fit a new thrust washer into the top swivel pinbush with the black P.T.F.E. coatinguppermost. Check it is in position when fittingthe top swivel pin. From 1991 model year fitnew thrust washers and thrust bearing.47. Hang the swivel pin bearing housing oil sealand retainer plate over the back of thehousing. Ensure they are in the correctassembly order.48. Fit a new joint washer and secure the swivelpin bearing housing to the axle. Starting withthe top fixing dowel bolt. Tighten evenly tothe correct torque.58The preload on bearings to be 0,25 to 0,30mm (0.010 to 0.012 ins), without the swivelhousing oil seal and axle fitted, and readingfrom the centre of the swivel assembly fromlock to lock to be 2.0 to 2.8 Nm (18 to 25in.lbs). Adjust by removing or adding shims tothe top swivel pin.To take a reading use special tool LST 141torque test adaptor, with a torque wrench andextension as shown./57 u , ‘Fit swivel pin housing49.50.51.52.53.54.. . ..,. ‘. .,.>:., 55.,:’ 7 .‘. ‘_.. 56.Grease and fit the lower swivel pin bearing tothe bearing housing.Place the swivel pin housing in position overthe swivel pin bearing housing.Using a new joint washer, fit the lower swivelpin with lip outboard. Do not secure withscrews at this stage.Fit a new sensor bush and new oil seal, lipside leading to the top swivel pin.Lubricate with a recommended oil and fit thetop swivel pin with existing shims.Coat the threads of the top swivel pin boltswith Loctite 542. Fit the bolts and jump hosebracket (do not tighten).Coat the threads of the lower swivel pinscrews with Loctite 270 and fit, together withthe damper and shield bracket. Tighten to thecorrect torque.Tighten the top swivel pin and brake jumphose bracket securing bolts to the correcttorque.RR2983MFit remaining components“L59. Liberally apply (do not pack) a recommendedgrease between the lips of the swivel housingoil seal.60. Secure the oil seal with the retaining plate andsecuring bolts tightening evenly to the correcttorque.ADDITION: SEPT. 89/REVISED: SEPT. 90 17


-KEY TO DRIVE SHAFT AND SWIVEL ASSEMBLY1.2.3.4.5.6.7.8.9.10.11.12.13.14.Brake caliper.Mud shield.Stub axle.feint washer.Oil seal.Bearing.Brake disc shield.C.V. joint.Circlip.Bush.Inner drive shaft.Top swivel pin and jump hose bracket.Shim.Swivel pin housing.RR2936M15. Joint washer.16. Lower swivel pin.17. Damper and shield bracket.18. Thrust washer.19. Bush and housing.20. Swivel pin bearing housing.21. Lower swivel pin bearing.22. Oil .seal.23. Oil seal retaining plate.24. joint washer.25. Oil seal.26. Sensor bush.27. Thrust bearing.28. 1991 model year.16


FRONT AXLE & FINAL DRIVE61. Fit the track-rod and drag link and secure withnew split pins.62. Loosely fit the lock stop bolt for lateradjustment.63. Fit the brake disc shield. Leaving the middlefixing nut loose until the lock stop has beenset.Fit drive shaft and stub axle64. Insert the axle shaft, and when the differentialsplines are engaged, push the assembly home.CAUTION: Take care not to damage the axleshaft oil seals.65. Place a new joint washer in position on theswivel pin housing to stub axle mating face.Coat the threads of the stub axle bolts withLoctite 270.66. Fit the stub axle with the keyway at the I2o’clock position.CAUTION: Ensure that the constant velocityjoint bearing journal is butted against thethrust ring on the stub axle. Before the stubaxle is secured..F._ ”67. Place the mud shield in position and securethe stub axle to the swivel pin housing withthe six bolts and tighten evenly to the correcttorque.68. Fit the brake jump hoses to the brake jumphose bracket.69. To complete the assembly, follow instructionsto fit front hub on ABS fitted vehicles.70. Check that the swivel pin housing oil drainplug is tightly fitted and remove the filler andlevel plugs.71. Inject approximately 0,35 litres (0.6 pints) ofrecommended oil until the oil reaches thelevel hole. Fit and tighten the filler and levelplugs and wipe away any surplus oil.72. Set the steering lock-stop bolt to provide aclearance of 20mm (0.787in) between the tyrewall and radius arm. Tighten the locknut whichalso secures the brake disc shield.73. Fit the ABS brake sensor following theinstructions in the brake section.ADDITION: SEPT.89


POWER STEERING BOXRemove and refitService tools:Drop arm extractor-MS252ANOTE: It is important that whenever any part ofthe system, including the flexible piping, isremoved or disconnected, that the utmostcleanliness is observed.All ports and hose connections should besuitably sealed off to prevent ingress of dirt, etc.If metallic sediment is found in any part of thesystem, the complete system should be checked,the cause rectified and the system thoroughlycleaned.Under no circumstances must the engine bestarted until the reservoir has been filled. Failureto observe this rule will result in damage to thepump.FIT THE STEERING WHEEL ENSURING THAT THEDRIVE PEGS LOCATE IN THEIR RESPECTIVEHOLES ON THE REAR OF THE STEERING WHEEL.AFTER FINAL ALIGNMENT RECONNECT THEMULTI-PLUG TO THE CASSETTE, TIGHTEN THESTEERING WHEEL SECURING NUT AND FIT THETRIM PAD.Removing1.2.3.4.5.Park the vehicle on a level surface.Prop open the hood.Remove the filler cap from the power steeringfluid reservoir.Disconnect the fluid pipes from the pump.Drain and discard the fluid. Replace the fillercap.Disconnect the fluid feed and return pipesfrom the steering box.Metric pipe fittings are used with ‘0’ ring pipeends on the fittings to the steering box.Follow normal ‘0’ ring replacement procedure;. : ;:. whenever pipes are disconnected.. . .Ensure that compatible metric components areused when fitting replacement pipes.CAUTION: PRIOR TO REMOVING ANY OF THECOMPONENTS INCORPORATED IN THESTEERING LINKAGE, IT IS IMPERATIVE THAT THEROAD WHEELS ARE IN A STRAIGHT AHEADPOSITION AND THAT THE STEERING WHEEL ISTHEN REMOVED TO PREVENT THE CRUISECONTROL SPIRAL CASSETTE BEING WOUND UPOR DAMAGED IF THE STEERING LINKAGE ISINADVERTENTLY MOVED OR ROTATED.AFTER REFllTlNG STEERING LINKAGECOMPONENTS, THE ROAD WHEELS MUST BERE-POSITIONED STRAIGHT AHEAD BEFOREFllTlNG THE STEERING WHEEL, DO NOTRECONNECT THE MULTI-PLUG TO THE CASSETTEOR FIT THE TRIM PAD AT THIS STAGE. IF, AFTERTHE VEHICLE HAS BEEN DRIVEN, IT IS FOUNDTHAT THE STEERING WHEEL REQUIRESRE-POSITIONING, REMOVE THE WHEEL.RE-ALIGN THE DRIVE PEGS ON THE CRUISECONTROL CASSElTE BY SLIGHTLY ROTATINGTHE UPPER PART OF THE CASSE’ITE IN THEAPPROPRIATE DIRECTION UNTIL THE PEGS LIEHORIZONTAL TO THE STEERING COLUMN.6. Seal all disconnected hose connections toprevent ingress of foreign matter.7 lack up and support the chassis front end withaxle stands. Alternatively, raise the vehicle on ahoist.WARNING: Whichever method is adopted, it isessential that the wheels are chocked, theparking brake is applied, and low range selectedwith differential lock engaged.Continued-’


,ga, r(HI*uCROVER8.9.10.11.12.13.14.8,19Disconnect the drag fink from the drop armusing a suitable extractor.Remove the drop arm, using drop armextractor MS252A.Remove the pinch bolt attaching the universaljoint to the power steering box.Loosen the nut securing the tie bar to thechassis.Remove the bolts securing the tie bar to thesteering box and move the tie bar aside.Remove the fixings attaching the powersteering box to the chassrs side member.Withdraw the power steering box.22.23.25.26.27.Remove the sealing plug and refit the flexiblehose to the power steering pump.Ensure that the steering wheel is correctlyaligned when the wheels are in thestraight-ahead position.NOTE: II may be necessary to remove thesteering wheel and reposition on thesplines to obtain this condition. Seesteering wheel- remove and refit.Remove the filler cap from the power steeringfluid reservoir. Fill the reservoir to the oil levelmark on the dipstick attached to the filler capwith the recommended fluid (see Section 09)and bleed the power steering system. Seepower steering system-bleed.Check the liuid level and replace the filler cap.Check, and if necessary, adjust the steeringbox.Test the steering system for leaks. with theengine running, by holding the steering hardon full lock in both directions.CAUTION: Do not maintain this pressure formore than 30 seconds in any one minute, toavoid causing the oil to overheat and possibledamage to the seals.. \.,28. Close the hood.29. Road test the vehicle.RR2196E9;18Refitting15. Refit the steering box to the chassis sidemember and tighten the four Nyloc nuts tothe correct torque (see section 06-Torquevalues).16. Refit the tie bar to the steering box, andtighten the tie bar securing nut to the correcttorque (see section 06-Torque values).17. Reconnect the pinch bolt, attaching theuniversal joint to the power steering box, andtighten to the correct torque (see sectionOC-Torque values).18. Refit the drop arm.19. Refit the drag link and secure.20. Lower the vehicle to ground level.21. Remove the sealing. plugs and reconnect theflexible hoses to the steering box.2;.


.. .POWER STEERING BOX OVERHAULService tools:LSTl20 -‘C’ WrenchLSTll9 -Worm adjusting wrenchMS252A -Drop arm extractor606602 -Ring expander606603 -Ring compressor606604 -Seal saver, sector shaftR01015 -Seal saver, valve and wormR01016 -Torque setting toolDismantleI. Remove the steering box from the vehicle,and withdraw the drop arm.; .,. :‘,.6.7.8.9.10.11.Loosen the set screw retaining the rack padadjuster.Remove the rack pad adjuster.Remove the sector shaft adjuster locknut.Remove the sector shaft cover fixings.Screw in the sector shaft adjuster until thecover is removed.Slide out the sector shaft.:.. .:,Rotate the retainer ring, as necessary, until oneend is approximately 12 mm (0.500 in) fromthe extractor hole.Lift the cover retaining ring from the groove inthe cylinder bore, using a suitable pointed driftapplied through the hole provided in thecylinder wall.Complete the removal of the retainer ring,using a screwdriver.Turn on left lock until the piston pushes outthe end cover.12. Withdraw the piston. using a suitable boltscrewed Into the tapped hole in the piston.Continued_’,.:.REVISED: DEC. 87 3 .’.:.


‘.‘.,13. Remove the worm adjuster locknut using ‘C’Wrench, LSTI 20.14. Remove the worm adjuster using wrenchLSTll9.RANGt“*’ ROVER21. Remove the circlip and seals from the inputshaft housing bore..I..-‘. 1RR234SEIS.Tap the splined end of the shaft to free the16.17.18.19.bearing.Withdraw the bearing cup and caged ballbearing assembly.Withdraw the valve and worm assembly.Withdraw the inner bearing ball race andshims.Retain the shims for reassemblyInspecting22. Discard all rubber seals and providereplacements.NOTE: A rubber seal is fitted behind theplastic ring on the rack piston. Discard theseal and also the plastic ring and providereplacements.. .’lj:.;‘.‘;:Steering box seals20. Remove the circlip and seals from the sectorshaft housing bore.AR23!5OE fs ’NOTE: Do not remove the sector bushesfrom the casing, Replacement parts are notavailable.‘ ‘. ‘.-.i :.:! *..I...‘.....4 REVISED: DEC. 87:.’ .


STEERING 157 1.:Steering box casingSector shaft cover assembly‘.23. Examine the piston bore for traces of scoringand wear.24. Examine the inlet tube thread for damage. Ifrepair is necessary this can be undertaken byusing a suitable tap.25. Examine the feed tube for signs of cracking.31. The cover, bush and seat are supplied as acomplete assembly for replacement purposes.Sector shaft adjuster locknut32. The locknut functions also as a fluid seal, anew nut be fitted at overhaul.Valve and worm assemblySector shaft assembly2333. Examine the valve rings which must be freefrom cuts, scratches and grooves. The valverings should be a loose fit in the valvegrooves.34. Remove the damaged rings ensuring that nodamage is done to the seal grooves.35. If required, fit replacement rings, using thering expander 606602. Warm the rings andexpander tool to aid assembly, using hot waterfor this purpose. Fit the rings to the expander,slide the expander over the valve and wormassembly, in turn fit the rings to theirrespective grooves. Remove the expander,slide the valve and worm assembly into thering compressor 606603 and allow the rings to26. Check that there is no side play on the rollers.27. If excessive side play on the roller does existfit a new sector shaft.28. Check the condition of the adjuster screwthreads.29. Examine the bearing areas on the shaft forexcessive wear.30. Examine the gear teeth for uneven orexcessive wear.NOTE: The expander will not pass over ringsalready fitted. The rings must be discardedto allow access and then new rings must befitted.Continued *’,_-; ,:(.’REVISED: DEC. 87 5


Il-l 57 STEERING.\, .# .VL“*’ ROVER36. Examine the bearing areas for wear. The areasmust be smooth and not indented.37. Examine the worm track which must besmooth and not indented.38. Check for wear on the torsion bar assemblypins; no free movement should exist betweenthe input shaft and the worm.NOTE: Any sign of wear makes it essentialthat a new valve and worm assembly isfitted.43. To remove the inner bearing cup and shimwashers, jar the steering box on the workbench, or use a suitable extractor.NOTE: Should difficulty be experienced atthis stage, warm the casing and the bearingassembly. Cool the bearing cup using asuitable mandrel and jar the steering boxon the bench.Rack thrust pad and adjusteri “I44. Examine the thrust pad for scores.45. Examine the adfuster for wear in the pad seat.46. Examine the nylon pad for distortion andadjuster set screw assembly for wear.46/ ‘P:.,;,aRR932M*Ball bearing and cage assemblies39. Examine the ball races and cups for wear andgeneral condition.40. If the ball cage has worn against the bearingcup, fit replacements.41. Bearing balls must be retained by the cage.42. Bearings and cage repair are carried out by thecomplete replacement of the bearings andcage assembly.Rack and piston47.48.49.50.Examine for excessive wear on the rack teeth.Ensure the thrust pad bearing surface is freefrom scores and wear.Ensure that the piston outer diameters are freefrom burrs and damage.Examine the seal and ring groove for scoresand damage.:‘.:‘. .‘,6 REVISED: DEC. 87


51. Fit a new rubber ring to the piston. Warm the Sector shaft sealwhite nylon seal and fit this to the piston.52. Slide the piston assembly into the cylinderwith the rack tube outwards. Allow to cool.ReassembleNOTE: When fitting replacement oil seals, thesemust be lubricated with recommended fluid.Also ensure that absolute cleanliness is observedduring assembly.Input shaft oil seal53. Fit the seal, lipped side first, into the housing.When correctly seated, the seal backing will lieflat on the bore shoulder.54. Fit the extrusion washer and secure with thecirclip.55. Fit the oil seal, lipped side first.56. Fit the extrusion washer.57. Fit the dust seal, lipped side last.58. Fit the circlip.RRQ38M,53Fitting the valve and worm assembly59. If removed, refit the original shim washer(s)and the inner bearing cap. Only PetroleumJelly may be used as an aid to assembling thebearings.RR2362Ex’ INOTE: If the original shims are notavailable, fit shim(s) of 0.76 mm (0.030 in)nominal thickness.ContinuedREVISED: DEC. 87 7.


1987 RANGEROVER60. Fit the inner cage and bearings assembly.61. Fit the valve and worm assembly, using sealsaver RQ1015 to protect the input shaft seal.62. Fit the outer cage and bearings assembly.63. Fit the outer bearing cup.63Fitting the rack and piston68.69.70.Screw a slave bolt into the piston head for useas an assembly tool.Fit the piston and rack assembly so that thepiston is 63.5 mm (2.5 in) approximately fromthe outer end of the bore.Feed in the sector shaft using seal saver606604 aligning the centre gear pitch on therack with the centre gear tooth on the sectorshaft. Push in the sector shaft, and, at thesame time rotate the input shaft about a smallarc to allow the sector roller to engage theworm.64. Fit a new worm adjuster sealing ring andloosely screw the adjuster into the casing. Fitthe locknut, but do not tighten.65. Turn in the worm adjuster until the end-floatat the input is almost eliminated.66. Measure and record the maximum rollingdistance of the valve and worm assembly,using a spring balance and cord coiled aroundthe torque setting tool ~01016.67. Turn in the worm adjuster to increase thefigure recorded in instruction 66 by 1.8 to 2.2kg (4 to 5 lb) at 1.250 in (31.7 mm) radius tosettle the bearings, then back off the wormadjuster until the figure recorded in instruction66 is increased by 0.9 to 1.3 kg (2 to 3 lb)only, with locknut tight. Use worm adjustingwrench LSTl19 and ‘C’ wrench LSTI 20.RRS41Ha REVISED: DEC. 87


Fitting the rack adjuster71. Fit the sealing ring to the rack adjuster.72. Fit the rack adjuster and thrust pad to engagethe rack. Back off a half turn on the adjuster.73. Loosely fit the nylon pad and adjuster setscrew assembly to engage the rack adjuster.NOTE: Before tightening the fixings, rotatethe input shaft about a small arc to ensurethat the sector roller is free to move in thevalve worm.78. Fit the cover fixings and tighten to the correcttorque (see section 06-Torque values).Fitting the cylinder cover79. Fit the square section seal to the cover.80. Remove the slave bolt fitted at operation 68and press the cover into the cylinder justsufficient to clear the retainer ring groove.81. Fit the retainer ring to the groove with oneend of the ring positioned I2 mm (0.5 in)approximately from the extractor hole.RR942MFitting the sector shaft cover74.75.76.77.Fit the sealing ring to the cover.Screw the cover assembly fully on to thesector shaft adjuster screw.Position the cover on to the casing.Tap the cover in place. It necessary back offon the sector shaft adjuster screw to allow thecover to joint fully with the casing. RR944M I IIContinued9 .i:,;.


RANGElg8’ ROVER. . . .. .Adjusting the sector shaftTorque peak checkI,82.83.84.as.86.87.Set the worm on centre by rotating the inputshaft half the total number of turns from eitherlock.Rotate the sector shaft adjusting screwcounter-clockwise to obtain backlash betweenthe input shaft and the sector shaft.Rotate the sector shaft adjusting screwclockwise until the backlash is just eliminated.Measure and record the maximum rollingresistance at the input shaft, using a springbalance, cord and torque tool ROlOl6.Hold the sector shatt adjuster screw andloosely tit a new locknut.Turn in the sector shaft adjuster screw untilthe figure recorded in instruction 85 isincreased by 0.9 to 1.3 kg (2 to 3 lb) with thelocknut tightened.With the input shaft rotated from lock-to-lock, the .‘.. ’ ”roliing resisiance torque figures should be greatestacross the centre position (1.5 turns approximatelyfrom full lock) and equally disposed about thecentre position.The condition depends on the value of shimmingfitted between the valve and worm assembly innerbearing cup and the casing. The original shimwasher value will give the correct torque peakposition unless major components have beenreplaced.Procedure90. With the input coupling shaft toward theoperator, turn the shaft fully -‘>counter-clockwise.91. Check the torque figures obtained fromlock-to-lock using a spring balance cord andtorque tool R01016.‘5Y‘. ., ,:Adjusting the rack adjusteraa. Turn in the rack adjuster to increase the figurerecorded in instruction 87 by 0.9 to 1.3 kg (2to 3 lb). The final figure may be less than7.25 kg (16 lb) but must not exceed thisfigure.89. Lock the rack adjuster in position with the setscrew.Adjustments92. Note where the greatest figures are recordedrelative to the steering position. If the greatestfigures are not recorded across the centre oftravel (i.e. steering straight-ahead position),adjust as follows:.,,:. .‘.


: If the torque peak occurs before the centreposition, add to the shim washer value; if thetorque peak occurs after the centre position,subtract from the shim washer value.Shim washers are available as follows:O.O3mm, O.O7mm, 0.12mm and 0.24mm (0.0015 in,0.003 in, 0.005 in and 0.010 in).NOTE: Adjustment of 0.07mm (0.003 in) to theshim value will move the torque peak area by l/4turn approximately on the shaft.3. Check and correct the reservoir fluid level.NOTE: During the carrying out of items 4, 5and 6, ensure that the steering reservoir iskept full. Do not increase the engine speedor move the steering wheel.4. Run the engine at idle speed, loosen thebleed screw. When fluid seepage past thebleed screw is observed, retighten the screw.93.94.95.96.Fit the drop arm to the steering box using anew tab washer. Tighten the nut to the correcttorque (see section OC-Torque values)andbend over tab.Refit the steering box to the vehicle.Replenish the system with the correct grade offluid. Refer to Recommended Lubricants andPower Steering System-bleed.Test the system for leaks, with the enginerunning, by holding the steering hard on fulllock in both directions.NOTE: Do not maintain this pressure formore than 30 seconds in any one minute toavoid overheating the fluid and possiblydamaging the seals.97. Road test the vehicle.POWER STEERING SYSTEMBleed1. Fill the steering fluid reservoir to theappropriate level marking on the dipstick withone of the recommended fluids.2. Start and run the engine until it attains normaloperatingtemperature.Ensure that the fluid level is in alignment withthe mark on the dipstick.Wipe off all fluid lost during bleeding.Check all hose connections, pump andsteering box for fluid leaks under pressure byholding the steering hard on full lock in bothdirections.CAUTION: Do not maintain this pressure formore than 30 seconds in any one minute, toavoid causing the oil to overheat andpossible damage to the seals. The steeringshould be smooth. lock-to-lock in bothdirections, that is, no heavy or light spotswhen changing direction when the vehicleis stationary.(-any out a short road test. If necessary,repeat the complete foregoing procedure.11


.RANGElg8’ ROVERPOWER STEERING SYSTEMProcedure.,. ITest 1.If there is a lack of power assistance for thesteering the pressure of the hydraulic pump shouldbe checked first before fitting new components tothe system. The fault diagnosis chart should also beused to assist in tracing faults in the power steeringsystem. 2.SERVICETOOLSHY23 -Pressure gaugejD10-2 -Test adaptorLSTlO-11 -Thread adaptor3.4.9.The hydraulic pressure gauge in conjunctionwith the test adaptor is used for testing thepower steering system. This gauge is calibratedto read up to 140 kgflcm’ (2000 p.s.i.) and thenormal pressure which may be expected in thepower steering system is 77 kgflcm’ (1100p.s.i.).Under certain fault conditions of the hydraulicpump it is possible to obtain pressures up to105 kgf/cm’ (1500 p.s.i.). Therefore, it isimportant IO realise that the pressure upon thegauge is in direct proportion to the pressurebeing exerted upon the steering wheel. Whentesting, apply pressure to the steering wheelvery gradually while carefully observing thepressure gauge.Check, and if necessary replenish, the fluidreservoir.Examine the power steering units andconnections for leaks. All leaks must berectified before attempting to test the system.Check the steering pump drive belt forcondition and tension, rectify as necessar)‘.Assemble the test equipment and fit to thevehicle, as shown in the diagram.Open the tap in the adaptor.Bleed the system but exercise extreme carewhen carrying out this operation so as not tooverload the pressure gauge.With the system in good condition, thepressures should be as follows:,. .Y.RR10‘14EL-JAA. Steering box.B. Steering pump.C. Existing hose, steering box to pump.D. Hose JDIO-3A.E. Test adaptor JDIO-2.F. Pressure gauge HY23.G. Thread adaptor LSTIO-11.H. Thread adaptor LSTl O-l I.(a) Steering wheel held hard on full lock andengine running at 1,000 rev/min, thepressure should be 70 to 77 kgflcm’ (1000to 1100 p.s.i.).(b) With the engine idling and the steeringwheel held hard on full lock, the pressureshould be 28 kgflcm’ (400 p.s.i.) minimum.I’*i‘I.’:,’ ‘, .,.;..’12


These checks should be carried out first on onelock, then on the other.CAUTION: Under no circumstances must thesteering wheel be held on full lock for morethan 30 seconds in any one minute, otherwisethere will be a tendency for the oil to overheatand possible damage to the seals may result.10.11.12.13.Release the steering wheel and allow theengine to idle. The pressure should be below7 kgf/cm’ (100 p.s.i.1.If the pressures recorded during the foregoingtests are outside the specified range, orpressure imbalance is recorded, a fault exist inthe system. To determine if the fault is in thesteering box or the pump, close the adaptortap for a period not exceeding five seconds.If the gauge fails to register the specifiedpressure, the pump is at fault and a new unitmust be fitted.Repeat the foregoing test after fitting a newpump and bleeding the system. If pumpdelivery is satisfactory but low pressure or asubstantial imbalance exists, the fault must bein the steering box valve and worm assembly.ADJUST POWER STEERING BOXNOTE: The condition of adjustment which mustbe checked is one of minimum backlash withoutovertightness when the wheels are in thestraight-ahead position.1. Jack up the front of the vehicle until thewheels are clear of the ground and supportthe chassis with axle stands.WARNING: It is essential that the wheels arechocked, the parking brake applied, and lowrange selected with differential lock engaged.2.3.Gently rock the steering wheel about thestraight-ahead position to obtain the ‘feel’ ofthe backlash present. This backlash must notbe more than 9.5mm (0.375 in).Continue the rocking action while an assistantslowly tightens the steering box adjuster screwafter loosening the locknut until the steeringwheel movement is reduced to 9.5mm (0.375in) maximum.4. Tighten the locknut,. then turn the steeringwheel from lock to lock and check that noexcessive tightness exists at any point.5. Lower the vehicle to ground level and removethe wheel chocks.6. Road test the vehicle. .:


.:) RANtiE.< :“I .,:lg8’ ROVER. . . _j:;:i .*POWER STEERING FLUID RESERVOIRRemove and refitRemoving1.2.3.4.Place a drain tray beneath the power steeringbox.Prop open the hood.Remove the reservoir filler cap.Disconnect the return hose from the steeringbox. Drain the fluid completely from thereservoir, reconnect the hose.‘:,ICAUTION: Power steering fluid is harmful topaintwork Should any fluid seep onto body,. chassis, or any other components. immediatelywipe clean. It is most important that fluiddrained from the power steering system is notre-used.5. Refit the return hose to the steering box.6. Release the pinch bolt and remove thereservoir from the bracket.7. Release the hose clamps and remove theflexible hoses, withdraw the reservoir from theengine compartment.NOTE: If the reservoir is not to be refittedimmediately, the hoses must be sealed toprevent the ingress of foreign matter.NOTE: The reservoir contains an integral filterwhich is not serviceable, however, in normal usethe reservoir unit should last the life of thevehicle. Should the power steering systemmalfunction and under inspection it is foundthat the steering fluid has been contaminated byforeign matter a new FLUID RESERVOIR MUST befitted.Refitting8. Reconnect the flexible hoses to the reservoir.Tighten the hose clamps securely.9. Relit the reservoir to the bracket and tightenthe pinch bolt securely.10. Ftll the reservoir to the prescribed level on the~I~SIIC~ with one of the recommended fluids(\ts( tlon 09) and bleed the power steering,L \ttlrn See Power Steering System-bleed.11. t II Ihe reservoir filler cap.12 C Io\e the hood.. . . .*- :;3,_ .‘. .,‘.__ ’.j‘.‘..,,I : ‘.‘.’.:::,14


POWER STEERING PUMP DRIVE BELTAdjustProcedure1.2.3.4.5.Prop open the hood and disconnect thebattery negative lead.Check, by thumb pressure, the belt tensionbetween the crankshaft and the pump pulley.There should be a free movement of between4 to 6mm (0.19 to 0.25 in).Loosen the two nuts at the side of the pumpto allow the pump to be pivoted.Loosen the bolt securing the pump lowerbracket to the slotted adjustment link.Pivot the pump (in the direction of the boldarrow) as necessary and adjust until the correctbelt tension is obtained.POWER STEERING PUMP DRIVE BELTRemove and refitRemoving or preparing for the fitting of a new .belt.1.2.3.4.5.Prop open the hood and disconnect thebattery negative lead.Loosen the idler pulley bolt and remove thefan belt.Loosen the alternator mountings and removethe drive belt.Loosen the power steering pump mountings.Pivot the pump and remove the drive belt.CAUTION: Do not use the pump casing as apoint of leverage when tensioning the powersteering drive belt. Damage to the pump casingmay be caused leading to fluid leakage.Refitting6. Locate the driving belt over the crankshaft andpump pulleys.7. Adjust the position of the pump to give adriving belt tension of 4 to 6mm (0.19 to 0.25in) movement when checked by thumbpressure midway between the crankshaft andpump pulleys.6. Maintaining the tension, tighten the pumpadjusting bolt and the top pivot nuts.NOTE: Check the alternator drive belttension after adjusting the power steeringpump belt.7. Reconnect the battery negative lead and closethe hood.NOTE: Check adjustment after runningengine at fast idle speed for 3 to 5 minutesif a new belt has been fitted.CAUTION: Do not use the pump casing as apoint of leverage when- tensioning the powersteering drive belt. Damage to the pump casingmay be caused leading to fluid leakage.8. Maintaining the tension, tighten the pumpadjusting bolt and the top pivot nut.9. Refit the fan belt and ad/ust the tension togive 4 to 6mm (0.19 to 0.25 in) movementwhen checked by thumb pressure midwaybetween the crankshaft and water pumppulleys.ContinuedREVISED: MAY 8915


-lc57 STEERINGI1987 KANbtROVER10.11.Refit the alternator drive belt and adjust togive 4 to 6mm (0.19 to 0.25 in) movementwhen checked midway between the powersteering pump and alternator pulleys.Reconnect the battery negative lead and closethe hood.NOTE: Check adjustment after runningengine at fast idle speed for 3 to 5 minutesif a new belt has been fitted.6STEERING PUMPNOTE: The power steering pump is not aserviceable item. In the event of failure ordamage a new pump must be fitted.Remove and refit.,, .)iRemoving1.2.3.4.5.6.7.8.Disconnect the battery negative lead.Loosen the alternator pivot bolts andadjustment link bolts, pivot the alternatorinwards and remove the drive belt.Loosen the water pump drive belt idler pulleyand remove the drive belt.Remove the left hand bank spark plug leadsand detach the distributor cap, place the leadsand cap to one side.Disconnect the electrical plug from thedistributor amplifier unit.Loosen the two nuts securing the powersteering pump pivot bracket.Release the three bolts securing the pulley tothe steering pump, do not remove them atthis stage.Release the bottom adjustment bolt below thesteering pump and pivot the pump inwardstowards the water pump to enable the drivebelt to be removed.9. Remove the three bolts with plain washersretaining the pulley to the pump and withdrawthe pulley.NOTE: Place a drain tray underneath thevehicle to catch any power steering fluidwhich will seep from the pump when thefluid pipe is disconnected.CAUTION: Power steering fluid is harmful topaintwork. Should any fluid seep onto the body, -. ‘-‘


o;;; 1987STEERING 5711.12.Remove the three bolts securing the pump tothe pivot bracket, maneuver the pump out ofthe bracket and withdraw it from the enginecompartment as far as the remainingconnected fluid hose will permit.Release the clamp securing the hose to thePump, remove the hose and plug bothopenings to prevent ingress of dirt.16.17.18.Fit the pulley to the steering pump driveflange, coat the three bolts with Loctite and fitto the steering pump, do not-fully tighten thebolts at this stage.Refit the crankshaft to steering pump drivebelt, pivot the steering pump outwards totension the belt, tighten the pivot boltssecurely. Check that the belt deflectsapproximately 4 to 6 mm (0.19 to 0.25in)when checked by thumb pressure midwaybetween the crankshaft and pump pulleys.Tighten the three steering pump pulleyretaining bolts to the specified torque (seesection 06-Torque values).Reverse the remaining removal instructions.Bleed the power steering system.Test the power steering system for leaks withthe engine running, holding the steering onfull lock in both directions.CAUTION: Do not maintain this pressure formore than 30 seconds in any one minute, toavoid causing the oil to overheat and possibledamage to the seals.Refitting13. Remove the plug from the fluid hose andsecure the hose to a NEW pump. Tighten thehose clamp securely.14. Maneuver the pump into the pivot bracket andsecure in position with the three retainingbolts. Tighten the bolts to the specified torque(see section 06-Torque values).15. Remove the plugs from the fluid pipe andsteering pump openings and fit the pipe.Tighten the pipe securely.22. Close the hood.23. Road test the vehicle.CAUTION: Care should be taken to ensure thatthe high pressure fluid pipe is well clear of boththe drive belt and the top of the power steeringbox.


1987 KANbtROVERPOWER STEERINGFAULT DIAGNOSISSYMPTOM CAUSE TEST ACTION CUREINSUFFICIENT POWER (I) Lack of fluid Check hydraulic fluid If low, fill and bleed theGSISTANCE WHEN tank level systemPARKING(2) Driving belt Check belt tension Adjust the driving belt(3) Defective hydraulicpump(a) Fit pressure guageof pressure is outsidebetween highlimits (high or low) afterpressure hose and checking items I and 2,steering pump with see Note 2steering held hard onfull lock, see Note 1and ‘Power SteeringSystem Test’(b) Release steeringwheel and allowengine to idle. See‘Power SteeringSystem Test’If pressure is greater,check box for freedomand self- centering actionPOOR HANDLINGWHEN VEHICLE IS INMOTIONHYDRAULIC FLUIDLEAKSLack of castor action This is caused by It is most important that(wheels will not return to over-tightening the this screw is correctlycentre) rocker shaft backlash adjusted. Seeadjusting screw on top instructions governingof the steering box adjustmentDamaged pipework, Check by visual Tighten or renew asloose connecting unions inspection; leaks from necessaryetc.the high pressure Irnesare best found whileholding the steering onfull lock with enginerunning at fast idle speed(See Note 1)NOTE: Leaks from the steering box tend to show Check ‘0’ rings on Renew as necessaryup under low pressure conditions, that is, engine pipeworkidling and no pressure on steering wheelContinued18


STEERING 57 rlSYMPTOM CAUSE TEST ACTION CUREEXCESSIVE NOISE (1) If the high pressure Check the loose runs of Alter hose route orhose is allowed to the hoses insulate as necessarycome into contactwith the body shell,or any componentnot insulated by thebody mounting,noise will betransmitted to thecar interior(2) Noise from hydraulic Check oil level and bleed If no cure, changepump system hydraulic pumpNote I. Never hold the steering wheel on full lock for more than 30 seconds in any one minute, to avoidcausing the oil to overheat and possible damage to the seals.LowNote 2. High pressure-pressure-In general it may be assumed that excessive pressure is due to a fault in thehydraulic pump.Insufficient pressure may be caused by one of the following:1. Low fluid level in reservoir ) Most usual cause of2. Pump belt slip ) insufficient pressure3. Leaks in the power steering system4. Hydraulic pump not delivering correct pressure5. Fault in steering box valve and worm assembly6. Leak at piston sealing in steering box7. Worn components in either steering box or hydraulic pumpSteering pumpMake/type ......................................................................... Hobourn-Eaton series 200Operating pressure - straight ahead position - at idle ...... 7 kgf/cm’ (100 p.s.i.1 maximumFull lock (left or right) at idle ............................................ 28 kgf/cm’ (400 p.s.i.) minimumFull lock (left or right) 1000 rev/min ................................. 70-77 kgflcm’ (1000-1100 p.s.i.).i‘9.::.


_. I..,987 KANCitROVERCOUPLING SHAFT AND UNIVERSAL JOINTSRemove and refitCAUTION: PRIOR TO REMOVING ANY OF THECOMPONENTS INCORPORATED IN THESTEERING LINKAGE, IT IS IMPERATIVE THAT THEROAD WHEELS ARE IN A STRAIGHT AHEADPOSITION AND THAT THE STEERING WHEEL ISTHEN REMOVED TO PREVENT THE CRUISECONTROL SPIRAL CASSETTE BEING WOUND UPOR DAMAGED IF THE STEERING LINKAGE ISINADVERTENTLY MOVED OR ROTATED.NOTE: Do not dismantle the upper couplingjoint. The steering shaft, rubber couplingand top universal joint is only available asan assembly.AFTER REFITTING STEERING LINKAGECOMPONENTS, THE ROAD WHEELS MUST BERE-POSITIONED STRAIGHT AHEAD BEFOREFll-FlNC THE STEERING WHEEL, DO NOTRECONNECT THE MULTI-PLUG TO THE CASSETTEOR FIT THE TRIM PAD AT THIS STAGE. IF, AFTERTHE VEHICLE HAS BEEN DRIVEN, IT IS FOUNDTHAT THE STEERING WHEEL REQUIRESRE-POSITIONING, REMOVE THE WHEEL.RE-ALIGN THE DRIVE PEGS ON THE CRUISECONTROL CASSETTE BY SLIGHTLY ROTATINGTHE UPPER PART OF THE CASSETTE IN THEAPPROPRIATE DIRECTION UNTIL THE PEGS LIEHORIZONTAL TO THE STEERING COLUMN.FIT THE STEERING WHEEL ENSURING THAT THEDRIVE PEGS LOCATE IN THEIR RESPECTIVEHOLES ON THE REAR OF THE STEERING WHEEL.AFFER FINAL ALIGNMENT RE-CONNECI-MULTI-PLUG TO THE CASSETTE, TIGHTENSTEERING WHEEL SECURING NUT AND FIT‘TRIM PAD.RemovingTHETHETHE1. Ensure the road wheels are in the straightahead position.NOTE: To gain access to the coupling shaftit is necessary to remove the air flow sensorand air filter canister.2. Remove one pinch bolt from the top universaljoint to the steering column.3. Remove two pinch bolts from the loweruniversal joint.4. Maneuver the coupling shaft top universaljoint up the steering column splines to releasethe lower joint from the steering box splines.Withdraw the shaft from the steering columnsplines.5. Withdraw the lower universal joint from thecouplingshaft.6. Inspect both universal joints for wear andexcessive play, fit new joints if necessary.7. Inspect the rubber coupling for condition -rubber deterioration, fit a new rubber couplingRefittingassembly if necessary.NOTE: When refitting the universal joints totheir respective components ensure that thepinch bolt holes line up with theirrespective grooves.8. Position the lower universal joint on the shaft.9. Position the shaft assembly toward the end ofthe steering column, maneuver the assemblyup the steering column splines until it ispossible to locate the lower universal jointonto the steering box splines. ,;0. Locate the bolt holes in the universal jointswith their respective grooves in the steeringcolumn, coupling shaft and steering boxsplines.I 1. Fit the pinch bolts, and tighten to the correcttorque (see section 06-Torque values).‘1.~‘İ20:-:.:


.’,’STEERING WHEELRemove and refitCAUTION: PRIOR TO REMOVING ANY OF THECOMPONENTS INCORPORATED IN THESTEERING LINKAGE, IT IS IMPERATIVE THAT THEROAD WHEELS ARE IN A STRAIGHT AHEADPOSITION AND THAT THE STEERING WHEEL ISTHEN REMOVED TO PREVENT THE CRUISECONTROL SPIRAL CASSETTE BEING WOUND UPOR DAMAGED IF THE STEERING LINKAGE ISINADVERTENTLY MOVED OR ROTATED.AFTER REFllTlNG STEERING LINKAGECOMPONENTS, THE ROAD WHEELS MUST BERE-POSITIONED STRAIGHT AHEAD BEFOREFllTlNG THE STEERING WHEEL! DO NOTRECONNECT THE MULTI-PLUG TO THE CASSElTEQR FIT THE TRIM PAD AT THIS STAGE. IF, AFTERTHE VEHICLE HAS BEEN DRIVEN, IT IS FOUNDTHAT THE STEERING WHEEL REQUIRESRE-POSITIONING, REMOVE THE WHEEL.RE-ALIGN THE DRIVE PEGS ON THE CRUISECONTROL CASSETTE BY SLIGHTLY ROTATINGTHE UPPER PART OF THE CASSETTE IN THEAPPROPRIATE DIRECTION UNTIL THE PEGS LIEHORIZONTAL TO THE STEERING COLUMN.:.:‘. FIT THE STEERING WHEEL ENSURING THAT THEDRIVE PhGS LOCATE IN THEIR RESPECTIVEHOLES ON THE REAR OF THE STEERING WHEEL.AFTER FINAL ALIGNMENT RE-CONNECT THEMULTI-PLUG TO THE CASSElTE, TIGHTEN THESTEERING WHEEL SECURING NUT AND FIT THETRIM PAD.RemovingService Tools:1BG tot4 Steering wheel remover18G 1014-2 Adaptor pinsNOTE: The steering column is of a ‘safety’type and incorporates shear pins. Thereforedo not impart shock loads to the steeringcolumn during removing and refitting thesteering wheel or at any time.4.5.6.Disconnect the cruise control electricalmulti-plug located in the small opening belowthe centre retaining nut.While holding the steering wheel remove theretaining nut and serrated washer.Extract the steering wheel using service tool18G 1014. Ensure the extractor pins areinserted in the threads up to shoulder of thepins.CAUTION: IT IS IMPERATIVE THAT THE UPPERPART OF THE CRUISE CONTROL CASSElTE ISNOT ROTATED AFTER THE STEERING WHEEL ISREMOVED. TO PREVENT ROTATION SECURE THEUPPER AND LOWER PART OF THE CASSElTE INPOSITION WITH ADHESIVE TAPE.RefittingEnsure the road wheels are in the straightahead position.Place the steering wheel on the columnsplines and remove the previously appliedadhesive tape to the spiral cassette.Ensure the two drive pegs on the upper partof the cassette align with their respectivelocation holes on the underside of thesteering wheel, ease the wheel onto the pegs.1.2., 3.Disconnect the battery negative lead.Ensure the road wheels are in the straightahead position to enable the steering wheel tobe fitted in its correct location on re-assembly.Carefully ease the centre trim pad off thesteering wheel.. . .:”RR1@26EContinued- 21


KAN


:PO;;: 1987STEERING 57,>.Refitting9. Position the sealing gasket on the end of thecolumn assembly.10. Feed the steering shaft through the floorboard and engage the drive splines at thecoupling shaft.11. Fit the column upper fixings, do not full)tighten at this stage.12. Fit the column lower fixings, do not fullytighten at this stage.13. Tighten the lower fixings to the specifiedtorque (see section 06-Torque values).14. Fit universal joint pinch bolt, and tighten tothe correct torque (see section 06-Torquevalues).15. Tighten the column upper fixings to thespecified torque (see section 06-Torquevalues).16. Reverse 1 to 4.STEERING COLUMN LOCK ASSEMBLYFIT THE STEERING WHEEL ENSURING THAT THEDRIVE PEGS LOCATE IN THEIR RESPECTIVEHOLES ON THE REAR OF THE STEERING WHEEL.AFrER FINAL ALIGNMENT RE-CONNECT THEMULTI-PLUG TO THE CASSETTE, TIGHTEN THESTEERING WHEEL SECURING NUT AND FIT THETRIM PAD.Removing1. Disconnect the batter)l negative lead.2. Carefully detach the steering wheel centrecover and using service tool 18C1014 andadaptor pins remove the steering wheel.CAUTION: IT IS IMPERATIVE THAT THE UPPERPART OF THE CRUISE CONTROL CASSElTE ISNOT ROTATED AFTER THE STEERING WHEEL ISREMOVED. TO PREVENT ROTATION SECURE THEUPPER AND LOWER PART OF THE CASSElTE INPOSITION WITH ADHESIVE TAPE.‘2’.T’Remove and refitService tool:18G1014 Extractor for steering wheel.18C1014-2 Adaptor pins.For ignition/starter switch-remove and refit asdescribed in Electrical Section 86.CAUTION: PRIOR TO REMOVING ANY OF THECOMPONENTS INCORPORATED IN THESTE’ERING LINKAGE, IT IS IMPERATIVE THAT THEROAD WHEELS ARE IN A STRAIGHT AHEADPOSITION AND THAT THE STEERING WHEEL ISTHEN REMOVED TO PREVENT THE CRUISECONTROL SPIRAL CASSETTE BEING WOUND UPOR DAMAGED IF THE STEERING LINKAGE ISINADVERTENTLY MOVED OR ROTATED.3. Release the fixings securing the shroud to thesteering column and withdraw the shroud.4. Release the column switches from the switchhousing to gain access to the column lockfixings.5. Using a sharp punch and a hammer, lightly tapthe head of the shear pins in acounter-clockwise direction to release themfrom the column lock housing.,.--;AFTER REFllTlNG STEERING LINKAGECOMPONENTS, THE ROAD WHEELS MUST BERE-POSITIONED STRAIGHT AHEAD BEFOREFITrING THE STEERING WHEEL, DO NOTRECONNECT THE MULTI-PLUG TO THE CASSElTEOR FIT THE TRIM PAD AT THIS STAGE. IF, AFTERTHE VEHICLE HAS BEEN DRIVEN, IT IS FOUNDTHAT THE STEERING WHEEL REQUIRESRE-POSITIONING, REMOVE THE WHEEL.RE-ALIGN THE DRIVE PEGS ON THE CRUISECONTROL CASSElTE BY SLIGHTLY ROTATINGTHE UPPER PART OF THE CASSElTE IN THEAPPROPRIATE DlRECTlON UNTIL THE PEGS LIEHORIZONTAL TO THE STEERING COLUMN.6. Remove the sheared bolts.7. Detach the upper cap.8. Withdraw the lower column lock assembly.Continued.’”.:.:.,:,. :;,:,.>,: ;. . .; .23‘.;


RANGEls8’ ROVERRefitting,. .,’ ‘,’‘.9.10.11.12.13.Position the steering lock upper cap on theouter column, locating the spigot in the holeprovided.Place the lower lock assembly into thecolumn.Fit the shear bolts to retain the cap and lock.Tighten the bolts sufficient to shear off theheads.Reverse 1 to 4.DROP ARMRemove and refit.’Service tools:MS252A Drop arm extractorRemovingRefitting1. Place the vehicle on a suitable hydraulic hoist,alternatively raise the front of the vehicle usinga hydraulic floor jack and install axle standsunder the front axle, remove the floor jack.2. Disconnect the drag link from the drop armball joint, using a suitable extractor.4. Set the steering box in the midwaylock-to-lock position.5. Fit the drop arm in position, aligning themaster splines.6. Fit the drop arm fixings and tighten to thecorrect torque (see section 06-Torque values).7. Fit the drag link and tighten to the correcttorque (see section 06-Torque values).DROP ARM BALL JOINTOverhaulThe drop arm ball joint can be overhauled with arepair kit available which consists of the thefollowing items:53. Remove the drop arm from the steering boxrocker shaft, using extractor MS252A.Ball pinRetainerSpring ringsDust coverBall top socketDismantleBall lower socketSpring‘0’ ringCover-plateCirclipNOTE: The drop arm ball joint is integralwith the drop arm.I Remove the drop arm from the vehicle andc Ipan the exterior.2 Rfbrncl\,e the spring rings and prise off the dustC-OVt’I.:3 In rhe Interests of safety, position the ball jointunder a press to relieve the spring tension andsupport the housing both sides of the ball pin,as illustrated. Apply pressure to the cover plateand remove the circlip and slowly release thepressure.:WARNING: Personal injury could result if the “- ‘:;circlip is removed without pressure beingapplied and maintained to the cover plate.Continued‘.,..:.24


Sf1382M4. Remove the spring, top socket and ‘0’ ring.5. Since the ball pin cannot be removed with theretainer in position, tap the threaded end ofthe ball pin to release the retainer and toremove the pin from the housing.STl38lMKEY TO BALL JOINT1. Spring rings2. Dust cover3. Bill housing4. Retainer5. Bottom socket6. Ball pin7. Top socket8. Spring9. ‘0’ ringlo. Cover-plate11. Circlip25,‘.‘.


.”iRANGE“” ROVER6. Using a sharp-edged punch or chisel, drive theball lower socket from the housing.7. Clean the housing and remove any burrs.13. Press the retainer onto the ball pin so that thetop edge is level with the edge of the taper.‘.’ .’Assemble8. Press in the lower socket squarely up to theshoulder.9. Dip the ball in Duckhams LB10 grease, orequivalent and fit to the housing and packwith grease.10. Fit the top socket.11. Fit the spring, small diameter towards the ball.12. Fit the ‘0’ ring and using the same method asfor removing the circlip, compress the coverplate and secure with the circlip. Ensure thatthe circlip is fully seated in the machinedgroove14. Fit the dust cover and retain with the twospring rings.15. Fit the drop arm to the steering box using anew lock washer. Tighten the retaining nut tothe correct torque (see section 06-Torquevalues)and bend over the lock washer.16. Assemble the ball pin to the drag link, seeinstructions for fitting drag link and track rod,tighten the castle nut to the correct torque(see section 06-Torque values)and secure witha new cotter pin.: ‘,:_.:


RR;;:; 19871STEERING 57TRACK ROD AND LINKAGE 11 6 5,8 10 5.8 6,9.’ Remove and refitTRACK RODRemoving1. Place the vehicle on a suitable hydraulic hoist,alternatively raise the front of the vehicle usinga hydraulic floor jack and install axle standsunder the front axle, remove the floor jack.2. Disconnect the steering damper at the trackrod.3. Disconnect the track rod at the ball joints,using a suitable extractor.4. Withdraw the complete track rod.Refitting8.9.IO.11.12.Fit the replacement parts. Do not tighten theclamp pinch bolts at this stage.Screw in a ball joint to the full extent of thethreads.Set the adjuster dimensionally to the track rodas illustrated, to 8.9mm (0.350 in).Set the adjuster end ball joint dimensionally, asillustrated to 28.57mm (1.125 in).The track rod effective length of 1230.0mm(48.4 in) is subject to adjustment during thesubsequent wheel alignment check.TRACK RODRefitting,I.LINKAGERemoving5. Loosen the clamp bolts.6. Unscrew the half joints.7. Unscrew the track rod adjuster, left handthread.13. Fit the track rod and tighten the ball joint nutsto the correct torque (see section 06.Torquevalues).14. Check the front wheel alignment.15. Reverse 1 and 2.CAUTION: A new track rod must be fitted if theexisting track rod is damaged or bent. Noattempt should be made to repair or straightenit..i


RANGE1g87 ROVERSTEERING DAMPERRemove and refitRemovingPlace the vehicle on a suitable hydraulic hoist,alternatively raise the front of the vehicle usinga hydraulic floor jack and place axle standsunder the front axle, remove the floor jack.Remove the fixings at the differential casebracket.Remove the fixings at the track rod bracket.Withdraw the steering damper.RR1509MDRAG LINK ENDSRemoving6. Loosen the clamp bolts.7. Unscrew the ball joint.8. Unscrew the offset end.sRRl943E- F ”8 6.9 7Refitting5. Reverse 1 to 4.DRAG LINK AND DRAG LINK ENDSRemove and refitRemoving1. Place the vehicle on a suitable hydraulic hoist,alternatively raise the front of the vehicle usinga hydraulic floor jack and place axle standsunder the front axle-remove the floor jack.2. Remove the right hand front road wheel.3. Disconnect the drag link ball joint at the swivelhousing arm, using a suitable extractor.4. Disconnect the drag link end at the drop armball joint, using a suitable extractor.5. Withdraw the drag Imk.RR 1509MRefitting9. Fit the replacement ends. Do not tighten theclamp bolts at this stage.10. Set the ball joint dimensionally to the draglink, as illustrated, to 28.57mm (1.125 in).11. Adjust the offset end to obtain the nominaloverall length of 919.0mm (36.2 in). The finallength is adjusted during refitting..:


DRAG LINKSTEERING LOCK STOPSRefittingCheck and adjust12. Fit the drag link. Tighten the ball-joint nuts tothe correct torque (see section 06-Torquevalues).13 Check, and if necessary, set the steering lockstops.14. Turn the steering and ensure that full travel isobtained between the lock stops. Adjust thedrag link length to suit.15. Using a mallet, tap the ball joints in thedirection indicated so that both pins are in thesame angular plane.16. Tighten the clamp bolts to the correct torque(see section 06-Torque values).Checking1. Measure the clearance between tyre wall andradius arm at full lock. This must be 20 mm(0.787 in).J16RR1041E / ’Adjusting. ‘_ IRRlSlOM17. Reverse 1 and 2.'w'2.3.4.5.Loosen the stop bolt locknut.Turn the stop bolt in or out as required.Tighten the locknut.Check the clearance between tyre wall andradius arm on each lock.CAUTION: A new drag link nmust be fitted if theexisting drag link is damaged or bent. Noattempt should be made to repair or straightenit..I(..:.;.::.,. : .:q.. . :REVISED: MARCH 9029‘,.’ ‘.‘. .,.


.KAN(rt“*’ ROVERFRONT WHEEL ALIGNMENTCheck and adjustCheckingToe-out dimensionsNOTE: No Adjustment is provided forcastor, camber or swivel pin inclinations.Set the vehicle on level ground with the roadwheels in the straight-ahead position.Push the vehicle back then forwards for ashort distance to settle the linkage.Measure the toe-out at the horizontalcentre-line of the wheels.Check the tightness of the clamp bolt fixingsfor the correct torque (see section 06-Torquevalues).Adjusting6.7.8.9.Loosen the adjuster sleeve clamp.Rotate the adjuster to lengthen or shorten thetrack rod.Check the toe-out setting as in instructions 1to 4. When the toe-out is correct lightly tapthe steering linkage ball joint, in the directionsillustrated, to the maximum of their travel toensure full unrestricted working travel.Finally, tighten the clamp bolts to correcttorque (see section 06-Torque values).X-Y-l,2~to,2,44p1m,tr 010 to020 \,,RR2172Ei.-.1I‘.: ,,.,.. ”. . .30 ’ REVISED: MARCH 90:::.


PO;;; 1987FRONTSUSPENSION,,’ _:.:. . _-. . .SELF LOCKING NUTSMany steering and suspension items are securedusing self locking nuts. Where self locking nutshave been removed, they MUST be replaced withnew items of the correct type.PANHARD RODRemove and refitRemoving1.2.3.4.Working underneath the vehicle remove thefixings at the mounting arm.Remove the fixings at the axle bracket.Withdraw the Panhard rod.Using a suitable hydraulic or bench press anda piece of metal tubing slightly smaller thanthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.RADIUS ARMRemove and refitRemovingLoosen the road wheel retaining nuts.Raise the front of the vehicle using a suitablehydraulic floor jack. Support chassis onsuitable stands and remove the wheel,(remove both front wheels only if removingboth radius arms).Support the front axle weight using thehydraulic floor jack.Remove the fixings - radius arm to chassis sidemember.i’ ---RR983M5. Disconnect the track rod at the ball joint,using a suitable extractor.6. Remove the fixings, radius arm to axle.7. Lower the radius arm front end to clear theaxle and remove it from the vehicle.._ .. ..(’..’Refitting5. Fit replacement bushes centrally in the rod.CAUTION: When pressing in the new bushesensure that pressure is applied to the outer edgeof the bush only and not to the rubber inner.6. Reverse 1 to 4. Tighten the fixings to thecorrect’torque (see section 06-Torque values).ContinuedREVISED: jULY 88 1


FRONT SUSPENSION1987 PO;;;8. Using a suitable hydraulic or bench press anda piece of metal tubing slightly smaller than*_..Refirtmgthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.9. Fit the replacement bushes centrally in thearm.4. Remove the shock absorber lower fixing andwithdraw the cupwasher, rubber bush andseating washer.5. Remove the four shock absorber bracketfixings.6. Withdraw the shock absorber and bracketcomplete.LLCAUTION: When pressing in the new bushesensure that pressure is applied to the outer edgeof the bush only and not to the rubber inner.10. Reverse 1 to 7. Tighten the fixings to thecorrect torque (see section OC-Torque values).‘..’;’FRONT SHOCK ABSORBERRemove and refitRemovingI. Loosen the road wheel retaining nuts.2. Raise the front of the vehicle using a suitablehydraulic floor jack. Support the chassis onsuitable stands and remove the road wheel.(Remove both front wheels only if removingboth shock absorbers).3. Support the front axle weight using thehydraulic floor jack.7. Withdraw the lower seating washer, rubberbush and cupwasher.8. Remove the fixings, shock absorber tomounting bracket.9. Withdraw the mounting bracket.10. Lift off the top seating washer, rubber bushand cupwasher.Refitting .;11. Reverse instructions 1 to 10.(‘,,;...,(, ”2REVISED: JULY 88::. ,’ :


.RR;;;; 1987FRONT SUSPENSION 60FRONT ROAD SPRINGBUMP STOPRemove and refitRemove and refitRemovingRemoving. ...’._,. ”1. Remove the front shock absorber.CAUTION: During the following procedure avoidover stretching the brake hoses. If necessary,loosen the hose connector locknuts to allow thehoses to follow the axle.1. Remove the fixings.2. Withdraw the bump stop assembly.‘,2. Lower the axle sufficient to free the roadspring.3. Withdraw the road spring.4. Withdraw the shock absorber bracket securingring.-57eRefitting3.4.Position the fixing bolts in the slots in thechassis brackets.Fit the bump stop assembly.RR1593MT'MRefitting5. Fit the shock absorber bracket retaining ring.Retain in position with a nut.6. Reverse 2 and 3.7. Remove the nut retaining the securing ring.8. Fit the front shock absorber..’:,‘.: ;::.:: > :‘.,, :‘.’ ‘:. ::3


RANGEFRONT SUSPENSION lggl ROVERANTI-ROLL BAR ASSEMBLY FRONT23 4KEY1. Anti-roll bar2. Rubber bush3. Strap4. Nut, bolt, washer5. Nut and washer6. Castellated nut and cotter pin7. Ball joint link armANTI-ROLL BAR FRONTRemove and refitRemove1. Mark for reassembly position of rubber busheson the anti-roll bar.2. Remove the tour nuts, bolts and washerssecuring the two bush straps.3. Remove the nuts, bolts, washers and rubberbushes from the ball joint links and removeanti-roll bar.Refit4. Position bushes on the anti-roll bar. Ensure thesplit points towards axle.5. Fit the anti-roll bar with the two straps. TOensure correct fit the angled sides of the barshould point down as shown. Loosely fit thebolts isashers and nyloc nuts.6 FII hrdt washers and rubber bushes. Usingne\\ IIUIS fit anti-roll bar to ball joint links.TIghivn to the correct torque.7 rlghlt~n to the correct torque the nutsWC urlng the straps..4ADDITION: SEPT. 90


;g; 1991FRONT SUSPENSIONANTI-ROLL BAR BALL JOINT LINKS-FRONT..‘.>),..‘.. .:Remove and refitRemove1. Remove the two nuts, bolts, washers andrubber bushes from the ball joint links.2. Remove cotter pin and loosen castellated nuta few turns.3. Release ball joint using special tool 18C 1063Aas shown.4. Remove castellated nut and ball joint link.4 1 2 II II:..,:;.RR2926MRefit,.:,5. Fit ball joint link and castellated nut. Ensurethe ball joint link arm points up. Tighten to thecorrect torque and fit new cotter pin.6. Align anti-roll bar to ball joint links.7. Fit bolts, washers and rubber bushes usingnew self locking nuts secure anti-roll bar toball joint links. Tighten to the correct torque.ADDITION: SEPT. SO


_:,.’ ..I‘1:,._.?’. . .’


.... ,...SELF LOCKING NUTSREAR SHOCK ABSORBERREAR SUSPENSION (64 1_'Many steering and suspension items are securedusing self locking nuts.Where self locking nutshave been removed, they MUST be replaced withnew items of the correct type.REAR ROAD SPRINGRemove and refitRemoving1.2.3.4.Loosen the rear road wheel retaining nuts.Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the chassis onstands and remove the wheels.Support the rear axle weight with the floorjack.Disconnect the shock absorbers at one end.Remove and refitRemovingLoosen the road wheel retaining nuts and raisethe rear of the vehicle using a suitablehydraulic floor jack.Support the chassis on stands. Remove theroad wheels and support the rear axle weightwith the floor jack.Remove the fixings and withdraw the shockabsorber frpm the axle bracket.‘.5. Position a suitable coil spring compressorcorrectly on the road spring.6. Compress the spring evenly to facilitateremoval.7. Lower the axle sufficient to free the roadspring from the upper seat.CAUTION: Avoid lowering the axle further thannecessary otherwise the rear brake flexible hosewil be damaged.8. Remove the spring retainer plate.9. Withdraw the road spring.10. Lift off the spring seat.RefittingJ51 l7M,i,:I’11. Reverse 1 to IO. Ensure that the cotter pinsecuring the top shock absorber mounting islocated in the inboard hole.REVISED: MARCH 90 1


REAR SUSPENSIONKANGE1987-90 ROVER4. Remove upper fixings. 2. Remove excessive mud deoosits fromunderneath the vehicle and any heavy itemsNOTE: j5llM shows 1990 Model Year top from inside the vehicle that are not part of thedamper fixing.original equipment.3. Measure the clearance between the rear axle5. Withdraw the shock absorber.bump pad and the bump stop rubber at the6. If required, remove the mounting bracket at front outer corner on both sides of thethe chassis side member.vehicle. The average clearance should be in7. If required, lift out the mounting rubbers at excess of 67mm (2.8 in). If it is less than thisthe upper end.figure remove the rear springs and check theirfree length against the ‘Road Spring Data’.RefittingReplace any spring whose free length is morethan 20mm (0.787 in) shorter than the figure8. Reverse items 7 and 6 as applicable.given. If after replacing a spring the average9. Reverse items 1 to 5. Vehicles up to 1990bump clearance is still less than 67mm (2.8 in),Model Year - when fitting the top shockreplace the IevellinR unit.absorber fixings compress the mountingrubbers and locate the cotter pin in theINBOARD hole. The outer hole is NOTdesigned for this purpose..LEVELLING UNITFunctionalcheckA Boge Hydromat levelling unit is located in thecentre of the red. .-.le.When the vehicle is unladen the levelling unit haslittle effect. The unit is self-energising and hencethe vehicle has to be driven before the unitbecomes effective, the time taken for this tohappen being dependent upon the vehicle load,the speed at which it is driven and the roughnessof the terrain being crossed.If the vehicle is overloaded the unit will fail to levelfully and more frequent bump stop contact will benoticed.Should the vehicle be left for a lengthy period, e.g.overnight, in a laden condition, it may settle. This isdue to normal internal fluid movement in the unitand is not detrimental to the unit performance.4.5.6.With the rear seat upright, load 450 kg (992lb) into the rear of the vehicle, distributing theload evenly over the floor area. Check thebump stop clearance, with the driving seatoccupied.Drive the vehicle for approximately 5 km (3miles) over undulating roads or graded tracks. ‘. ..Bring the vehicle to rest by light brake .application so as not to disturb the vehicleloading. With the driving seat occupied, checkthe bump stop clearance again.If the change in clearance is less than 20mm(0.787 in) the levelling unit-must be replaced.Before carrying out the checks below, verify thatthe vehicle is being operated within the specifiedmaximum loading capabilities. If the levelling unit isthen believed to be at fault, the procedure belowshould be followed.1. Check the levelling unit for excessive oilleakage and if present the unit must bechanged. Slight oil seepage is permissible.2 REVISED: MARCH 90


.,PO;;; 1987-90LEVELLINC UNITRemove and refitREARSUSPENSIONARemovingWARNING: The levelling unit containspressurized gas and must not be dismantled northe casing screws removed. Repair is byreplacement of complete unit only.1. Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the chassis onstands.2. Support the axle weight using the floor jack.3. Disconnect the suspension upper links at thepivot bracket.Refitting11. Coat the ball pin threads with ‘Loctite’ gradeCVX or suitable equivalent sealant.12. Reverse items 1 to 10. Do not fully tighten thefixings until all items are in their fittedposition. Finally tighten to the correct. torque(see section 06-Torque values).LEVELLING UNIT BALL JOINTSRemove and refitService tools:,-4.5.6.7.8.9.10.Ease up the lower boot.Unscrew the lower ball joint at the levellingunit push rod, using thin jawed wrenches.Remove the top bracket fixings at the crossmember.Withdraw the levelling unit and top bracketcomplete.Ease back the upper boot.Unscrew the upper ball joint at the levellingunit, using thin jawed wrenches.Withdraw the upper and lower boots and theirretaining spring rings.R01006 Extractor for axle bracket ball jointRemoving1. Remove the levelling unit.2. Remove the cotter pin and nut at the rear axlebracket.3. Extract the ball pin from the axle bracket usingExtractor R01006.3


REAR SUSPENSION4. Withdraw the pivot bracket complete with balljoints.5. Unscrew the ball joint assembly for thelevelling unit.6. Remove the ball joint assembly from the axlebracket.RANGE1987-90 RO”ER‘.a,RR1605M7.8.9.10.11.RefittingReplacement ball joints are supplied ascomplete assemblies, less fixings, and arepre-packed with grease.The ball joint for the axle bracket must not bedismantled.The ball joints for the levelling unit may bedismantled and cleaned if required.Pack the ball joint with Dextagrease GP or anequivalent grease when assembling.Ensure that the ball seating is square in itshousing before refitting.14. Fit the pivot bracket complete with ball jointsto the rear axle. Tighten to the correct torque(see section 06-Torque values).15. Fit the levelling unit.BUMP STOPRemove and refitRemoving1. Rernove the fixings.2. Withdraw the bump stop assembly.12.13.Press the knurled ball joint into the pivotbracket.Screw the ball joints for the levelling unit intothe mounting brackets. If the ball joints do notscrew in easily and fully, remove and theassemblies ensuring that the plastic seats donot jam in the housings. Tighten to the correcttorque (see section 06-Torque values).RR 1607MRefitting3. Position the fixing bolts in the ~101s in thechassis brackets.4. Fi+ the bump stop assembly, posrtion the _I . . . .snoulder on the carrier to suit tht: chassis !configuration.4


..’ :KnlYutROVER lg8’ REAR SUSPENSIONUPPER SUSPENSION LINK Replacing the bush.:..::..‘),’ :‘,.. .’ .:?,:.I. ‘.. ‘.’x.’,/Remove and refit 1 to 6 and 9BUSHRemove and refit 7 and 8Removing1. Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the rear of thechassis on stands allowing the axle to be freelysuspended.2. Remove the fixings, upper link bracket toframe.7. Using a suitable hydraulic or bench press anda piece of metal tubing slightly smaller thanthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.8. Fit the replacement bush assembly centrally inthe housing.CAUTION: When pressing in the new bushesensure that pressure is applied to the outer edge01 the bush only and not to the rubber inner.Refitting9. Reverse 1 to 6. Do not fully tighten the fixingsuntil all components are in position.10. Finally tighten all fixings to the correct torque(See Section 06 Torque Values).. . . . :-..3.4.5.6.Remove the fixings,bracket.upper links to pivotWithdraw the upper link complete with framebracket.Remove the fixing bolt.Separate link and bush assembly from bracket.REVISED: jUl.Y 88


l-l 64 REAR SUSPENSIONRANGE“*’ ROVERLOWER SUSPENSION LINK Replacing the bushRemove and refit 1 to 7, 10 to 12BUSHRemove and refit 8 and 9Removing1. Place the vehicle on a suitable hydraulic hoistfor accessibility.2. Alternatively, raise the rear of the vehicle usinga suitable hydraulic floor jack and support thevehicle using stands placed under the axle.3. Remove the link rear fixings.8. Using a suitable hydraulic or bench press anda piece of metal tubing slightly smaller thanthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.9. Fit the replacement bush assembly centrally inthe housing.CAUTION: When pressing in the new bushensure that pressure is applied to the outer edgeof the bush only and not to the rubber inner.Refitting10.11.12.Reverse items 6 and 7. Do not tighten thelocknut at this stage.Reverse items 3 to 5.Lower the vehicle, remove the jack and allowthe axle to take up its static laden position.Finally tighten the locknut to the correcttorque (see section 06-Torque values).RR1597M /"4. Remove the mounting bracket fixings at theside member bracket.5. Withdraw lower link complete with mountingbracket.6. Remove the locknut.7. Withdraw the mounting bracket from thelower link.6. REVISED: JULY 88


R”\$ 1991REAR SUSPENSIONANTI-ROLL BAR ASSEMBLY REARKEY1. Anti-roll bar2. Rubber bush3. Strap4. Nut, bolt, washer5. Nut and washer6. Ball joint link arm7. Bolt and washer8. Castellated nut and cotter pinANTI-ROLL BAR REARRemove and refitRemove1. Note for reassembly, the position of rubberbushes on the anti-roll bar.2. Remove the four nuts, bolts and washerssecuring the two bush straps.3. Remove the nuts, bolts, washers and rubberbushes from the ball joint links and removeanti-roll bar.Refit4. Position the rubber bushes on the anti-roll bar.Ensure the split points towards axle.5. Fit the anti-roll bar with the two straps. Ensurethe ball joint link arms point down as shown.Loosely fit, the bolts, washers and new nylocnuts.6. Fit bolt, washers and rubber bushes. Usingnew nuts fit anti-roll bar to ball joint links.Tighten to the correct torque.7. Tighten to the correct torque the nutssecuring the straps.,‘.:‘,.,,‘. .:ADDITION: SEPT. 90 7


REAR SUSPENSIONRANGE“” ROVER\::ANTI-ROLL BAR BALL JOINT LINKS-REARRemove and refit. .Remove,:’_’ ;’.:: .I,..:‘..‘. .:.‘.Remove the two nuts, bolts, washers andrubber bushes from the ball joint links andlower anti-roll bar to clear links.Remove cotter pin and loosen castellated nuta few turns.Release ball joint using special tool 18C 1063Aas shown.Remove castellated nut and ball joint link.Refit5. Fit ball joint link arm and castellated nut.Ensuring the ball joint link arm points down asshown.Tighten to the correct torque and fitnew cotter pin.6. Align anti-roll bar to ball joint links.7. Fit bolts, washers and rubber bushes usingnew self locking nuts secure anti-roll bar toball joint links. Tighten to the correct torque.,8 - ADDITION: SEPT. 90


:KAlYU,tROVER lg8’.BRAKE SYSTEM - DescriptionThe brake system fitted to Range Rovers is of theI.H. split type.Early 1987 Range Rover vehicles were fitted duringmanufacture with an Automotive Products (AP)master cylinder and servo assembly, together withassociated brake pipes and pedal box assembly.The brake failure warning system on the AP typemaster cylinder is a Pressure Differential WarningActuator (P.D.W.A.) switch, which is activated whenthe shuttle valve moves along its bore due topressure differential in either the primary orsecondary circuits caused by fluid loss or sealfailure. The result of the shuttle valve movement isto illuminate a brake failure warning light in theinstrument binnacle.Later 1987 models are fitted with an uprated LucasGirting type LSC 115 servo and 25,4mm AS/ASmaster cylinder plus associated brake pipes andpedal box assembly.The brake failure warning system on the LucasGirling type is a Fluid Level Warning Indicator(F.L.W.I.) which is incorporated into the fluidreservoir cap and is activated when fluid loss in thereservoir is sufficient so that the float in the switchdrops and in turn illuminates a brake failure warninglight in the instrument binnacle.NOTE: It should be noted that the two systemsare not interchangeable on a component bycomponent basis but must be changed as acomplete package, ie, servo, master cylinder,brake pipes and pedal box.The AP system can be found on pages :1-19 inclusive.reducing valve.A brake failure switch incorporated in the mastercylinder will illuminate a panel warning light if afailure occurs in either the primary or secondaryhydraulic circuits.The brake fluid reservoir is divided, the frontsection (section closest to the servo) feeds theprimary circuit and the rear section feeds thesecondary circuit. Under normal operatingconditions both the primary and secondaryhydraulic circuits operate simultaneously on brakepedal application. In the event 01 a failure in theprimary circuit the secondary circuit will stillfunction and operate front and rear calipers.Alternatively, if the secondary circuit fails, theprimary circuit will still function and operate theupper pistons in the front calipers.If the servo should fail, both hydraulic circuits willstill function but would require greater pedalpressure.The hand-operated parking brake is completelyindependent of the hydraulic circuits.Brake pad wear sensors are incorporated into thefront right and rear left hand side, inboard brakepads. The sensors will illuminate a brake pad wearwarning light in the instrument binnacle, when padthickness has been reduced to approximately 3mm(0.118 in).CAUTION: THOROUGHLY CLEAN ALL BRAKECALIPERS, PIPES AND FD-HNCS BEFORECOMMENCING WORK ON ANY PART OF THEBRAKE SYSTEM. FAILURE TO DO SO COULDCAUSE FOREIGN MATTER TO ENTER THE SYSTEMAND CAUSE DAMAGE TO SEALS, AND PISTONSWHICH WILL SERIOUSLY IMPAIR THE BRAKESYSTEM EFFICIENCY..tThe Lucas Girling system can be found on pages :31-42 inclusive.BRAKE SYSTEM - (Vehicles fitted with AP servo andmaster cylinder)To ensure the brake system efficiency is notimpaired the following warnings must beadhered to:-WARNING::.:‘.:.:‘..:. .:.’.: :‘.’_:. ., ‘:DescriptionThe hydraulic braking system fitted to the RangeRover is of the dual line type, incorporating primaryand secondary hydraulic circuits.NOTE: References made to primary andsecondary do not imply main service brakes oremergency brakes but denote hydraulic lineidentification.The brake pedal is connected to a vacuum-assistedmechanical servo which in turn operates a tandemmaster cylinder. The front disc brake calipers eachhouse four pistons, the upper pistons are fed bythe primary hydraulic circuit, the lower pistons bythe secondary hydraulic circuit. The rear disc brakecalipers each house two pistons and these are fedby the secondary hydraulic circuit via a pressureDO NOT use brake fluid previously bled fromthe system.DO NOT use old or stored brake fluid.ENSURE that only new fluid is used and that it istaken from a sealed container:DO NOT flush the brake system with any fluidother than the recommended brake fluid. (SeeLubricants, Fluids and Capacities Section 09).The brake system should be drained and flushedat the recommended service intervals. (SeeMaintenance Section 10).REVISED: JULY 87 11


1987 RANCEROVERPRIMARY HYDRAULIC CIRCUIT ,...._ \El SECONDARYHYDRAULIC CIRCUITWARNING: Some components on the vehicle,such as gaskets and friction surfaces (brakelinings, clutch discs or automatic transmissionbrake bands), may contain asbestos. Inhalingasbestos dust is dangerous to your health andthe following essential precautions must beobserved:-. Work out of doors or in a well ventilatedarea and wear a protective mask.. Dust found on the vehicle or producedduring work on the vehicle should beremoved by vacuuming and not by blowing.. Dust waste should be dampened, placed ina sealed container and marked to ensuresafe disposal.. If any cutting, drilling etc., is attempted onmaterialscontaining asbestos the itemshould be dampened and only hands toolsor low speed power tools used. . . . .; .i.,l.f‘, ’REVISED: JULY 87


BRAKE SYSTEM LAYOUT‘(.RRlB45EHOSES1. Front left hand flexible hoses.2. Front right hand flexible hoses.3. Intermediate flexible hose.PIPES,..; 4. Feed to front left hand hose connector.5. Feed to front right hand hose connector.‘.‘.’ :.:.::. 6. Feed to front left hand caliper.7. Feed to front right hand caliper.8. Feed to rear left hand caliper.9. Feed to rear right hand 5aliper.10. Feed to two way connector.11. Feed to intermediate hose.12. Feed to pressure reducing valve.13. Brake failure warning switch.. ..I.:.:.3 ’


‘.._ .’RANGE“*’ ROVERBRAKES: .:.::::Bleed.The hydraulic system comprises two completelyindependent sections. The rear calipers and thelower pistons in the front calipers form thesecondary section, while the upper pistons in thefront calipers form the primary section. Thefollowing procedure covers bleeding the completesystem, but it is permissible to bleed one sectiononly if disconnections are limited to that section.‘.Bleeding will be assisted if the engine is run or avacuum supply is connected to the servo.‘.’;’ ‘.,’ ;’.‘..:’ ,.,‘.WARNING: IF THE ENGINE IS RUNNING DURINGTHE BRAKE BLEEDING PROCESS ENSURE THATNEUTRAL GEAR IS SELECTED AND THAT THEPARKING BRAKE IS APPLIED.When bleeding any part of the secondary section,almost full brake pedal travel is available. Whenbleeding the primary section only, brake pedaltravel will be restricted to approximately half.WARNING: Before commencing to bleed thesystem it is necessary to loosen off the brakefailure warning switch to prevent the shuttlevalve damaging the switch unit.1. Disconnect the leads from the switch.2. Unscrew the switch and insert the ‘C’ washerbetween the switch and master cylinder beforedepressing the brake pedal.3. After completion of bleeding, remove the ‘Clwasher and screw in the switch and tighten tothe correct torque (see section 06-Torquevalues).NOTE: When bleeding the systemcommence with the caliper furthest fromthe master cylinder and bleed from thescrew on the same side as the fluid inletpipes, then close the screw and bleed fromthe screw on the opposite side of the samecaliper. Tighten the bleed screws to thecorrect torque. (see section 06.Torquevalues).Bleeding1. Fill the fluid reservoir with the correct fluid,see IData Section’.NOTE: The correct fluid level must bemaintained throughout the procedure ofbleeding2. Connect a bleed hose to the bleed screw onthe rear caliper furthest from the mastercylinder.3. Submerge the free end of the bleed hose in acontainer of clean brake fluid.4. Loosen the bleed screw.5. Operate the brake pedal -fully and allow toreturn..-NOTE: Allow at least five seconds to elapsewith the foot right off the pedal to ensurethat the pistons fully return beforeoperating the pedal again. ”‘.;4


,,..;.KWNbtROVER ls8’6. Repeat 5 until fluid clear of air bubblesappears in the container, then keeping thepedal fully depressed, tighten the bleed screw.7. Remove the bleed hose and replace the dustcap on the bleed screw.13.14.15.16.17.Connect a bleed hose to the other screw onthe front caliper furthest from the mastercylinder.Repeat 3 to 7 for the second secondary screwon the front caliper.Refit the front wheel.Repeat 9 to 15 for the front caliper nearest themaster cylinder.Remove the ‘C’ washer and tighten the PDWAswitch to the correct torque. (see section06-Torque values).BRAKE PRESSURE REDUCING VALVERemove and refitRemovingRR1646E8.9.10.11.12.Repeat 1 to 7 for the other rear caliper.Remove the front wheel on the side furthestfrom the master cylinder.Connect a bleed hose to the primary bleedscrew on the front caliper furthest from themaster cylinder.Connect a bleed hose to the secondary bleedscrew on the same side of the caliper as theprimary screw.Repeat 3 to 7 for the front caliper, bleedingfrom the two screws simultaneously.1. Remove all dust, grime, etc., from the vicinityof the pressure reducing valve fluid pipeunions.2. Disconnect the outlet fluid pipe from thepressure reducing valve. Plug the pipe andreducing valve port to prevent the ingress offoreign matter.3. Remove the valve from the three-wayconnector and plug both openings.4. Withdraw the pressure reducing valve from theengine compartment.iRRlO4TERefitting5. Reverse the removal instructions.6. Bleed the brake systems.NOTE: The pressure reducing valve is not aserviceable item, in the event of failure ordamage, a new unit must be fitted.ContinuedREVISED: DEC. 87 5..;.


i-l 70 BRAKESRANGElg8’ ROVERMASTER CYLINDER-OVERHAULCAUTION: Brake fluid is corrosive, if any fluidcomes into contact with body paintwork,immediately flush with a large quantity of waterand wipe clean with a soft cloth.1.2.3.Disconnect the brake pipes from the side ofthe master cylinder and plug the outlet ports.Disconnect the electrical plug from the PDWAswitch.Remove the two nuts and spring washerssecuring the cylinder to the servo unit.4. Remove the reservoir filler cap and drain off..-the surplus fluid.‘. !5. Remove the two screws securing the reservoirto the master cylinder.6. Lift the reservoir off the master cylinder.7. Carefully pry the two reservoir sealing rubbersfrom the master cylinder.8. Secure the master cylinder in a vice and pushthe primary piston down the bore andwithdraw the secondary piston stop pin. .9. Press down the primary piston and removecirclip.10. Withdraw the primary piston assembly.theRR839M11. Apply a high pressure air line to?he secondaryoutlet port to expel the secondary pistonassembly.6 ’ REVISED: DEC. 87


,..:.’ 1,(..’ .WARNING: Safety glasses must be worn. Do notoperate or direct the air line towards oneself orother personnel in the workshop. Apply a shortburst of air only, if the secondary piston is notexpelled from its bore repeat the aboveinstruction.:; ‘.c12. Remove the PDWA switch from the side ofthe master cylinder.13. Remove the large end plug and copper washerretaining the shuttle valve in the mastercylinder.14. Apply a high pressure air line to the primaryoutlet port to expel the shuttle valve from itsbore.WARNING: Safety glasses must be worn. Do notoperate or direct the air line towards oneself orother personnel in the workshop. Apply a shortburst of air only, if the shuttle valve is notexpelled from its bore repeat the aboveinstruction.,::..‘. .‘.1RR84oM.’Continued”,,‘..:(., :: ‘:I,’ ‘,’‘. :.I.,:: :,.’i . .


RANGE‘g87 ROVER” ,2RR 847MKEY TO MASTER CYLINDER: :’.\’,’1. Securing screws2. Reservoir3. Reservoir seals4. End plug5. Copper washer6. Shuttle valve7. Secondary piston stop pin8. Nuts and washers securing cylinder to servo9. Primary piston10. Circllp11. Secondary piston12. PDWA switch13. XI’ washer14. Plastic sleeve8


PRIMARY PISTON SEALS15. Remove the retaining screw from the primarypiston and remove the following items.(A) Spring retainer(6) Piston spring(C) Circlip(D) Seal retainer(E) Recuperating seal(F) Washer16. Taking care not to damage the piston, pry offthe outer seal.16SECONDARY PISTON SEALS19. Remove the following items from thesecondary piston:(A) Spring(8) Seal retainer(C) Recuperating seal(D) Washer20. Taking care not to damaRe the piston pry offthe outer seal./. ..-.17.18.Fit a new outer seal into its groove bysqueezing the seal between the finger andthumb into an oval shape and press the raisedpart of the seal over the flange using thefingers of the other hand.Fit a new recuperating seal and assemble theparts in reverse order of removal. Compressthe spring and secure the assembly with theretaining screw. Tighten the screw securely.21.22.Fit a new outer seal using the same procedureas for the primary piston outer seal bysqueezing the seal between the finger andthumb into an oval shape and press the raisedpart of the seal over the flange using thefingers of the other hand.Fit the recuperating seal assembly parts in thereverse order of removal.RR844MRR842MContinued.IREVISED: JULY 889-j,..


RANGElg8’ ROVERSHUTTLE VALVE ‘0’ RINGS23. Withdraw the plastic sleeve and carefullyremove the two ‘0’ rings from the valve takingcare not to damage the piston.ASSEMBLING MASTER CYLINDERIt is important that the following instructions arecarried out precisely, otherwise damage could becaused to the new seals when inserting theplungers into the cylinder bore. Generous amountsof new brake fluid should be used to lubricate theparts during assembly. Never use old fluid or anyother form of cleaning and lubricating material.Cleanliness throughout is essential.23RR845M24. Fit a new ‘0’ ring into the ‘0’ ring groove atthe centre of the valve. Fit the remaining ‘0’ring into the small groove at the end of thevalve. Do not fit the plastic sleeve at thisstage.NOTE: The ‘0’ rings should not be rolledalong the piston, but should be stretchedslightly and eased down the piston and intothe grooves.25. Clamp the cylinder in a vice and lubricate thesecondary piston seals and cylinder bore. Placethe piston assembly into the cylinder until therecuperation seal is resting centrally in themouth of the bore. Gently insert the pistonwith a circular rocking motion. as illustrated.While ensuring that the seal does not becometrapped, ease the seal into the bore andslowly push the piston down in onecontinuous movement.24fWl948E26. Slowly press the piston down the bore and fitthe secondary piston stop-pin.27. Fit the primary plunger assembly using thesame method as for the secondary plunger.Press the plunger down and secure theassembly with the circlip.NOTE: Insert the plastic sleeve into theshuttle valve bore, ensuring it seats at thebottom of the bore..‘.. 1. :i. j‘, :REVISED: JULY 88


”‘..:‘. ,.:.:::.,...‘. ., .’‘.‘.’1I’* ,:‘,‘:“.‘..,, :.28. Lubricate the ‘0’ rings and fit the shuttle valve.Fit the end plug using a new copper sealingwasher and tighten the plug securely.CAUTION: To prevent damage to the ‘0’ ring atthe end of the valve ensure it remains in thesmall groove until the valve reaches the smallplastic sleeve.29.30.31.32.‘.‘.‘.,.“:’33.Fit the plastic ‘C’ washer to the end of thePDWA switch and screw the switch into themaster cylinder.Fit new seals to the bottom of the reservoir.Press the reservoir into the lop of the mastercylinder and secure in position with the tworetaining screws.Fit the master cylinder to the servo and securewith the two nuts and spring washers andtighten to the correct torque (see section06-Torque values).Bleed the brakes, After final bleed remove the‘C’ washer from the PDWA switch and tightenthe switch to the correct torque (see section06-Torque values).Disconnect the servo operating rod from thebrake pedal.Remove the four nuts and spring washerssecuring the brake pedal and servo assembliesto the engine compartment closure panel.Withdraw the pedal assembly from the vehicle.DISMANTLING,,:. ,’...PEDAL ASSEMBLY-OVERHAULRemove the pedal assembly8.9.Disconnect the pedal return spring.Remove the circlip from the ID’ shaped end ofthe pedal shaft.10. Withdraw the pedal shaft.11. Withdraw the pedal from the box.‘.12::,3.4.Disconnect the battery negative lead.Remove the lower dash panel fixings, lowerthe panel to gain access to the electricalconnections at the rheostat switch and bulbcheck unit. Disconnect the leads and removethe lower dash from the vehicle, detach thetrim pad from around the pedal assembly.Disconnect the electrical leads from the stoplight switch.Remove the vacuum hose and disconnect theelectrical plug to the cruise control brake ventswitch..:,’.: ‘.3.i :,‘. ). ., ;::::.xRRlBSOEContinued .a,e- .:11


12. Remove the bushes from the pedal pivot tube.Assembling13. Press the new bushes into the pedal pivothose. ff necessary, ream the bushes to15.87mm plus 0.05mm (.625 in plus .002 in).14. Lightly oil the bushes and pedal shaft.Refit the pedal assembly15. Refit the assembly to the engine compartmentclosure panel, tighten the four nuts securely.16. Connect the electrical leads to the stop lightswitch.17. Connect the servo operating rod to the brakepedal with the pivot bolt eccentric, in theforward position. Do not fully tighten thepivot bolt nut.18. Turn the pivot bolt to bring the brake pedalback until it just contacts the rubber buffer,then secure the pivot bolt nut.19. Check the cruise control brake switch ventvalve setting (see ‘Setting Procedure’ inSection 19 Cruise Control)20. Clip the lower trim pad into position and refitthe lower dash.21. Re-connect the battery.12


‘..,.I.4 5I I 6,:’,’ ;’,‘,‘.‘, :RR848hlKEY TO BRAKE SERVO. . ,I “,,1. Push rod seal2. Retainer3. Push rod4. Non-return valve5. Seal6. Servo shell7. Clamp ring8. Locknut9. Lock washerIO. Support plate11. Diaphragm12. Backing washer13. Bearing retainer14. Nylon bearing15. Seal16. Separator shell17. Spring18. Diaphragm support and tubeI 9. Diaphragm20. Reaction piston21. Rubber ‘0’ ring22. Sponge seal23. Backing ring24. Rubber ‘0’ ring25. Levers26. Bearing ring27. Circlip28. Valve body29. Bearing retainer30. Nylon bearing31. Seal32. Servo cover33. Rubber ‘0’ ring34. Valve/push rod assembly35. Rubber boot013 ”..,’::


RANGE70 BRAKES “*’ ROVERI..:..BRAKE SERVO-OverhaulREMOVING THE SERVO1.2.3.4.53.6.7.Remove the master cylinder from the servo.Disconnect the servo vacuum hose from thenon-return valve.Remove the lower dash within the vehicle togain access to the brake pedal linkage andservo retaining nuts located on the rear of theengine compartment closure panel.Disconnect the brake pedal linkage.Remove the four nuts with spring washerssecuring the servo to the closure panel.Remove the servo from the enginecompartment and place on a suitable cleanbench.Thoroughly clean the exterior of the servo.CAUTION: CARE MUST BE TAKEN TO ENSURETHAT ALL COMPONENTS ARE SCRUPULOUSLYCLEAN BEFORE UNDERTAKING THE OVERHAULPROCEDURE. ANY DIRT OR GRIT WITHIN THESERVO COULD RESULT IN DAMAGE TO THEDIAPHRAGMS.DISMANTLING THE SERVO9.10.11.12.Remove the nut, bolt and plain washersecuring the clamp to the servo.Remove the rubber boot from the valve/pushrod assembly.Slide the servo cover off the valve body.Using two screwdrivers inserted between theseparator shell outer lip and servo shell,carefully lever the diaphragm assembly out ofthe shell.13. Bend back the tabs of the locking washer.‘.’8.Before dismantling the servo lightly scribeidentification marks on the servo shell, clampring and cover plate to aid the assemblyprocedure.WARNING: Assistance may be required, to holdthe diaphragm assembly together while thelocknut is released, to prevent the unitseparating due to internal spring pressure.14. Remove the locknut and separate theassembly.Continued


.’‘.‘.‘:.I ,.BRAKES l-l 70; .(; :15.:: ;:: “:..:+.‘. .‘*‘i.‘..:16.17.Remove the support plate, diaphragm andbacking washer from the separator shell.Pry the serrated bearing retainer out of theseparator shell.Remove the nylon bearing and rubber sealfrom the separator shell. Note their positionfor reassembly.23.24.25.26.Remove the sponge seal and backing ringfrom the valve body.Lift out the two levers and remove the bearingring.Release the circlip securing the valve/push rodassembly in the valve body.Carefully pry the end cap from the oppositeend 01 the valve body and withdraw thevalve/push rod assembly complete..)_,.:;,2’:‘...,.’..:’x, .:::,,. 1:’.: ” :..:,zv.:18. Remove the three screws, locknuts plain andfibre washers securing the diaphragm to thevalve body.19. Remove the diaphragm support and tube fromthe front of the diaphragm.20. Remove the diaphragm from the valve body.21. Pull the piston out of the valve body.22. Remove the ‘0’ rings from the valve body andpiston.1827. Remove the small ‘0’ ring from the assembly.RR855M. . .NOTE: The valve/push rod assembly cannotbe further dismantled, if the seals andassembly are in a poor condition, fit a newassembly.Continued. . ._./REVISED: APR. 87 15


RANGElg8’ ROVER*28. Remove the push rod, seal, washer andretainer from the servo shell.NOTE: If a new push rod is fitted theoperating length must be set after the servohas been assembled, see assemblingprocedure instruction number 61.30. Fit a new ‘0’ ring to the end of the valve. DONOT ROLL THE ‘0’ RING INTO THE ‘IGROOVE. Carefully stretch the seal and easeit down the valve and into the groove.RR857M; i31.32.Lubricate the seals with a suitable disc brakelubricant and push the assembly fully into thebore of the valve body.Clamp the eye of the assembly in a benchvice. Press the valve body down to expose thecirclip groove at the end of the valve/push rodassembly and fit the circlip.32:ASSEMBLE THE SERVOCarefully inspect all parts for wear and damage.Absolute cleanliness of all parts of the servo isessential.29. If a new valve/push rod assembly is beingfitted it will be necessary to compress thespring located in the centre of the valve, toenable the circlip to be inserted into thegroove, thus tensioning the seal.33. Fit the bearing ring (thicker of the two rings),levers, backing ring and sponge seal to thevalve body.” ,.,.,, > ;:..A, ;.;; ,.,‘:16 REVISED: APR. 87


. ...>.NOTE: Ensure that the chamfered edges ofthe levers are fitted firmly into the grooveat the end of the push rod assembly.34.35.36.37.Feed the sponge filter and felt pad into theopposite end of the valve body and press theend cap into position.Lightly coat the new valve body ‘0’ ring withdisc brake lubricant and ease the seal into thegroove.Lightly coat the new reaction piston ‘0’ ringwith disc brake lubricant and ease the seal intothe groove.Push the piston into the valve body ensuringthat the two projections on the piston arelocated over the levers in the valve body, pushthe piston firmly into position.40.Fit the three securing screws, washers andnuts, entering the bolts from the valve bodyside.NOTE: The fibre washer is inserted behindthe screw head.Tighten to the correct torque see sectionOC-Torque values.38.Place the new diaphragm onto the valve body,locating the inner diaphragm bore onto theshoulder just outside the three bolt holes.41.42.43.Coat the new nylon bearing and seal with asuitable disc brake lubricant and insert the sealinto the separator shell, with the open edge ofthe seal facing upwards.Fit the nylon bearing washer with thechamfered inner edge downwards.Using a suitable service tool, example M5550,press in the new retaining ring, convex sidefirst, until the retainer sits firmly on the nylonbearing.NOTE: DO NOT LUBRICATE THEDIAPHRAGM.39.Fit the diaphragm support plate and tube tothe valve body ensuring that the indent in thesupport plate lines up with the correspondingprojection on the valve body.Continued,.,_ i ,i: ‘,’ ‘.. . ..:.


l-l 70 BRAKES44. Fit the backing washer to the concave side ofthe separator shell diaphragm.45. Fit the diaphragm to the separator shell,concave side first, locate the sealing lip overthe edge of the separator.46. Place the support plate onto the face of thediaphragm.47. Mount the valve body into a bench vice.CAUTION: DO NOT OVERTIGHTEN THE VICE.USE JAW PROTECTORS/COVERS. Coat thesupport plate tube with disc brake lubricant.RANGElg8’ ROVER54. Locate the outer edge of the valve bodydiaphragm into the indent around theseparator shell and push the assembly into theservo vacuum shell, ensure that the diaphragmremains in position.If’48. Place the spring onto the valve body, largestdiameter to sit on support plate and tube.49. Holding the separator shell assembly togetherplace it on to the top of the spring.50. Compress the complete assembly until thethread on the end of the reaction pistonprotrudes beyond the separator shellassembly.51. Fit a new tab washer and screw on the largenut.55.Coat the new nylon bearing and seal for theservo end cover with disc brake lubricant andpress the seal into the cover.NOTE: THE OPEN FACE OF THE SEALDOWNWARDS.52. Remove the complete assembly from the vice.Tighten the locknut to the correct torque (seesection 06.Torque values).53. Bend up the tabs on the lock washer.56.57.58.59.Fit the new bearing retainer using a suitableservice tool example: MS550. Ensure theretainer sits firmly on top of the nylon bearing.Lightly coat the valve body with disc brakelubricant ease the end cover onto theassembly and align the identification marks.Locate the beaded edge of the diaphragmbetween the end cover and servo shell.Fit the clamp ring, bolt and nut, rotate the ringuntil the identification mark lines up withthose on the servo unit. Tighten the clampring to the correct torque (see section06-Torque values).Fit a new rubber boot over the valve/push rodassembly...I .,!., ,’18 ’.:


I .-..BRAKES 70 l-l60. Fit a new retainer, nylon washer and seal tothe push rod, fit the push rod to the servo.NOTE: Flat face of the seal to the bottom ofthe seal recess in the servo shell.65. Remove the small spacer. Increase or decreasethe size of the spacer accordingly until thecorrect dimension is attained.66. Coat the push rod seal with Lockheed discbrake lubricant and fit to the servo.(A) Retainer(B) Nylon washer(C) Seal,’AR064M3 i, .\l.(’1, ‘\.NOTE: If a new push rod is fitted, theoperating length must be checked, ifadjustment to the rod is required, adjust asfollows.67.68.69.70.71.72.73.Carefully pry the non-return valve and seal outof the servo shell.Fit new seal.Inspect the non-return valve for condition, fit anew valve if necessary.Fit non-return valve.install the servo into the vehicle and tighten allbolts to the correct torque (see section06-Torque values).Reconnect the servo operating rod to thebrake pedal with the pivot bolt eccentric inthe forward position, do not fully tighten thepivot bolt nut.Turn the pivot bolt to bring the brake pedalback until it just contacts the rubber thensecure the pivot bolt nut.:61. Run two nuts down the studs at the mastercylinder joint face of the servo. Set the top ofthe nuts to a dimension of 22.3-22.4 mm(0.876-0.881 inch).62. Lay a straight edge across the top of the twonuts. Check the height of the push rod to thebottom of the straight edge.63. If the push rod is out of the limits specifiedadjust as follows.64. Remove the push rod from the servo, clampthe small domed end of the rod in a benchvice and detach the main stem.REVISED: JUNE 87 19


-.RANGElg8’ ROVER%‘,,,. :,’ .‘.FRONT BRAKE CALIPER ASSEMBLY‘.‘.’ .’,. : .’. .,:.‘)7. 1.5.,‘.I.. ,.’,:,:L‘.’x._,.RR870MKEY TO CALIPER;: ; ,j,1. Caliper2. Bleedscrews3. Pad retaining springs4. Retaining pins5. Friction pads6. Pad wear indicator plug20REVISED: JUNE 677. Piston8. Wiper seal retainer9. Wiper sealIO. Fluid sealI I. Brake disc


BRAKES r70lREMOVE AND OVERHAUL FRONT BRAKECALIPERSService tool:18G672-Piston clampNOTE: Pad wear warning indicators areincorporated into the front and rear right handinboard pads.Remove caliper1.2.3.4.5.6.Loosen the front wheel retaining nuts, using asuitable hydraulic floor jack raise the front ofthe vehicle and lower onto axle stands andremove the wheels.Expose the two flexible brake hoses bymoving the coiied protective covering.Using a recognised hose clamp, clamp bothhoses to prevent loss of brake fluid,disconnect the rigid brake pipes from theflexible hoses, seal the ends of the hoses andpipe openings to prevent ingress of dirt. (Ifnecessary the two rigid brake pipes to thecaliper can be disconnected when the caliperis removed from the swivel pin housing).Disconnect the pad wear warning indicator(front right hand side only).Remove the retaining pins and springs,withdraw the pads. If the same pads are to berefitted, identify them for assembly to theiroriginal locations.Remove the two bolts and withdraw thecaliper from the disc.DISMANTLE AND OVERHAULDo not separate the caliper halves7. Clean the outer surfaces of the caliper withaerosol brake cleaner.8. Using special tool 18G672, clamp the pistonsin the inboard half of the caliper and gently,keeping fingers clear, and with CAUTION,apply air pressure to the fluid inlet port toexpel the rim half pistons. Since it is unlikelythat all pistons will expel at the same time,regulate the rate with a suitable piece of woodbetween the appropriate piston and caliper.RR669MContinued21


9. Finally, remove the pistons keeping themidentified with their respective bores.10. Remove the wiper seal retainer by inserting ablunt screwdriver between the retainer and theseal and pry the retainer carefully from themouth of the bore.11. Taking care not to damage the seal grooves,extract the wiper seal and fluid seal.12. Clean the bores, pistons and particularly theseal grooves with clean brake fluid or aerosolbrake cleaner only. If the caliper or pistons arecorroded or if their condition is not perfectnew parts must be fitted.Assemble outboard pistons13. Coat a new fluid seal with a suitable disc brakelubricant. Ease the seal into the groove in thebore using only the fingers and ensure that itis properly seated. The fluid seal and thegroove are not the same in section so thatwhen the seal is seated it feels raised to thetouch at the edge furthest away from themouth of the bore.14. Coat the appropriate piston with disc brakelubricant and insert it squarely into the bore byhand only. Do not tilt the piston duringinsertion and leave approximately 8mm (0.312inch) projecting from the bore,15. Coat a new wiper seal with disc brakelubricant and fit it to a new seal retainer. Slidethe assembly, seal first, over the protrudingpiston and into the bore recess. Remove thepiston clamp from the mounting half and usethe clamp to press home the seal retainer andpiston.Mounting inboard pistons16. Clamp the outboard pistons and carry out thesame procedure as for removing and fittingthe outboard pistons and seals, instructions 8to 15.Fit calipers and pads to vehicle17. Fit the caliper to the axle and secure with thetwo bolts tightening evenly to the correcttorque (see section 06-Torque values).18. Connect the brake flexible hoses to the caliperand tighten to the correct torque (see section06.Torque values).19. Remove the clamps from the hoses.20. Lightly coat the back and edges of the padswith a suitable disc brake lubricant carefullyavoiding the friction material.21. Insert the pads and retaining springs, secure inposition using new retaining pins and openout the ends. Note the correct position of theretaining springs.NOTE: Ensure that the friction pad with thewear indicator is fitted to the inboard sideof the front right hand caliper. . .,.a’.,.)22


.’22.23.24.25.26.Reconnect the pad wear indicator electricalplug.Bleed both the primary and secondary brakesystems. (Refer to page 4 for the brakebleeding procedure).When the foregoing instructions have beencompleted on all calipers, press the brakepedal firmly several times to locate the frictionpads.Fit the road wheels, remove the axle standsand finally tighten the road wheel nuts.Road test the vehicle, remembering that if newfriction pads have been fitted they are not‘bedde&in’ and may take several hundredmiles before the brakes are at maximumefficiency.RR2007EDismantle and overhaul.-I...’ ./._REMOVE AND OVERHAUL REAR BRAKE CALIPERSService tool:18C672-Piston clampRemove caliper1.2.3.4.5.6.Loosen the rear road wheel nuts and jack upthe rear of the vehicle, lower onto axle standsand remove the wheels.Using a recognised hose clamp, clamp theflexible brake hose above the rear axle, toprevent loss of fluid.Remove the brake pipe(s) from the rear brakecaliper(s). Seal the ends of the pipe to preventingress of dirt.Rear right hand caliper only, disconnect thepad wear indicator.Remove the retaining pins and springs andwithdraw the pads. If the same pads are to berefitted, identify them for assembly to theiroriginal locations.Remove the two bolts and withdraw thecaliper from the axle.Do not separate the caliper halves7. Clean the outer surfaces of the caliper withaerosol brake cleaner.8. WITH CAUTION expel the pistons from theirbores by applying air pressure to the fluid inletport. Since it is unlikely that both pistons willexpel at the same time, regulate the rate witha suitable piece of wood inserted between thetwo pistons.9. Finally, remove the pistpns keeping themidentitied with their respective bores.Continued.23


1987 RANGEROVER10. Remove the wiper seal retainer by inserting ablunt screwdriver between the retainer and theseal and pry the retainer carefully from themouth of the bore.I I. Taking care not to damage the seal grooves,extract the wiper seal and fluid seal.REAR BRAKE CALIPER ASSEMBLYLH Rear Caliper illustrated812. Clean the bores, pistons and particularly theseal grooves with clean brake fluid or aerosolbrake cleaner only. If the caliper or pistons arecorroded or their condition is not perfect newparts must be fitted.. .:RRZOOBEKEY TO CALIPER1. Caliper 6. Wiper seal retainer2. Bleed screw 7. Wiper seal3. Pad retaining springs8. Fluid seal4. Friction pads9. Retaining pins5. Piston24


BRAKES (70 1,13.14.1516Coat a new fluid seal with a suitable disc brakelubricant. Ease the seal into the groove in thebore using only the fingers and ensure that itis properly seated. The fluid seal and thegroove are not the same in section so thatwhen the seal is seated it feels raised to thetouch at the edge furthest away from themouth of the bore.Coat the appropriate piston with a suitabledisc brake lubricant and insert it squarely intothe bore by hand only. Do not tilt the pistonduring insertion and leave approximately 8mm(0.312 inch) projecting from the bore.Coat a new wiper seal with a suitable discbrake lubricant and fit it to a new seal retainer.Slide the assembly, seal first, over theprotruding piston and into the bore recess.Using special tool 18G672-piston clamp, presshome the seal retainer and piston.21. Insert the pads and retaining springs, secure inposition with new retaining pins and spreadthe ends. Note the correct position of theretaining springs.Mounting inboard piston’17. Carry out the same procedure as for removingand fitting the outboard piston and seals,instructions 8 to 16.Fit calipers and pads to vehicle18.19.20.Fit the caliper to the axle and secure with thetwo bolts tightening evenly to the correcttorque (see section 06-Torque values).Connect the brake pipes to the calipers andremove the clamp from the flexible brake hoseabove the rear axles, see section 06-Torquevalues for brake pipe to caliper tighteningtorque.Lightly coat the back and edges of the padswith disc brake lubricant carefully avoiding thefriction material.22.23.24.25.26.NOTE: Ensure that the friction pad with thewear indicator is fitted to the inboard sideof the rear right hand, brake caliper.Reconnect the pad wear indicator electricalmulti-plug.Bleed the secondary brake system at the rearcalipers, starting at the caliper furthest awayfrom the master cylinder.When the foregoing instructions have beencompleted on both calipers, press the brakepedal tirmly several times to locate the frictionpads.Fit the road wheels, remove the axle standsand finally tighten the road wheel nuts, (seesection 06 - Torque values).Road test the vehicle, remembering that if newfriction pads have been fitted they are not‘bedded-in’ and may take several hundredmiles before the brakes are at maximumefficiency.


PARKING BRAKE LEVERRemove and refitRemoving1.2.3.4.5.6.7.6.9.Disconnect the battery negative terminal.Chock the road wheels and release theparking brake.Open the glove box lid and remove the fourscrews securing the glove box liner to theouter surround and lift out the liner.Remove the two electrical leads at the rear ofthe glove box cigar lighter and release the twoheater hoses from their retaining clamps.Carefully pry the window lift switch panel awa)from the front of the glove box. Maneuver thepanel through the opening and into the insideof the glove box.Remove the main gear selector knob andtransfer gearbox knob.Carefully pry the centre panel out of thegearbox tunnel mounted console, anddisconnect the electrical multi-plug to theinset graphics panel, withdraw the panel offthe main gearbox selector.Remove the cotter pin, plain washer and clevispin securing the parking brake cable to theparking brake lever.Remove the four bolts and plain washers. Twoare located immediately behind the parkingbrake lever accessible from inside the glovebox. The remaining two bolts are locatedforward of the parking brake lever accessiblefrom the floor mounted console opening.10.11.12.13.14.RANGElg8’ ROVERRaise the parking brake lever to its uppermostposition and ease the glove box and consoleassembly rearwards to release the location tabfrom the radio housing, lift the assembly offthe gearbox tunnel.Disconnect the electrical lead from the parkingbrake warning switch.Release the parking brake cable outer retainingnut.Remove the remaining single bolt with plainwasher securing the front of the parking brakemounting bracket.Withdraw the parking brake lever assembly offthe parking brake outer cable.Refitting15.16.17.18.19.Fit the parking brake lever to the gearboxtunnel and secure in position with the singlebolt (with plain washer) forward of the levermounting bracket.Secure the outer parking brake cable to themounting plate and tighten the nut securely.Refit the glove box/console assembly andsecure in position, tightening the remainingbolt and two screws securely.Fit the inner parking brake cable to the parkingbrake lever using a new cotter pin.Reverse the remaining removal instructions,ensuring that the electrical wiring in the glovebox assembly is arranged to prevent it frombecoming trapped between any mating faces.: :. 1:_.._.. ^. ?-....‘$ . ._.26 .


‘..OVERHAUL PARKING BRAKEWARNING: Dodust from thefrom the brakerisk, if inhaled.DISMANTLINGnot use an air line to removebrake assembly. Asbestos dustlinings can be a serious health1. Disconnect the battery negative terminal andchock the road wheels for safety. Release theparking brake, select ‘P’ in main gearbox andrelease the parking brake.2 Disconnect the drive shaft from the outputflange.3. Loosen off the brake adjuster, remove the twoscrews and withdraw the brake drum. Inspectthe friction surface of the drum, turn ifexcessively scored or oval.13. Clean all parts in aerosol brake cleaner andallow to dry. Examine the components forwear and discard if unsatisfactory.Assemble expander assembly14. Grease and fit the expander and drawlink.15. Grease and fit the plungers and rollers, fittingthe plungers with the highest end of the rollergroove towards the backplate.Remove and overhaul adjuster assembly16.17.18.Remove the two bolts and withdraw theadjuster assembly from the back plate.Remove the plungers.Screw the adjuster cone inwards to removefrom the housing.‘.NOTE: If drum requires skimming themaximum diameter is 255.65 mm (10.06 in).4.5.6.Remove the cotter pin and clevis pinconnecting the parking brake inner cable tothe brake actuating lever.Remove the brake shoes complete withpull-off springs. Note position of springs inrelation to the shoes.Remove the four bolts securing back plate totransfer box and withdraw the back platecomplete with oil catcher.,’ .’Remove and overhaul expander assembly7. Remove the rubber dust cover.8. Remove the expander and drawlink.9. Remove the retainer spring plate.10. Remove the locking plate.11. Remove the packing plate and withdraw theexpander assembly from the back plate.12. Remove the two plungers and rollers.19. Thoroughly clean the parts in aerosol brakecleaner and discard any unsatisfactorycomponents.REVISED: JULY 88 27


RANGE“*’ ROVER,.‘,(.i. ..“\" !KEY TO PARKING BRAKE1. Brake drum2. Brake drum retaining screws3. Brake shoes4. Brake shoes pull-off springs5. Expander assembly6. Adjuster assembly7. Drawlink8. oil catcher9. Back plate and retaining bolts10. Dust coverI I. Locking plate12. Packing plate13. Spring plate-.i:,I.),j:...,A’ ‘1. 28 REVISED: JULY 88


..:‘...’ 4. I.Assembly adjuster assembly20. Grease and screw in the adjuster cone.21. Grease and fit the adjuster plungers and alignthe chamfered ends with the adjuster cone.Note that the two plungers are identical andcan be fitted lo either bore. Secure theassembly with a rubber band to prevent theplungers falling out.29. Fit new pull-off springs to the brake shoes andfit to the back plate.NOTE: That the fully lined end of the lowershoe must be toward the expanderassembly and the fully lined end of theupper shoe towards the adjuster assembly.ASSEMBLENOTE: If the brake linings are oil-soaked, fitnew brake shoes. Check and if necessary fita new output shaft oil seal.29


l-lRANGE70 BRAKES “*’ ROVERPARKING BRAKE CABLERemove and refitRemoving89Release the locknuts securing the parkingbrake outer cable to the retaining bracket.Release the outer cable from the ‘P’ clamplocated on top of the transfer gearbox, andwithdraw the cable assembly from the vehicle.-_. ,., i1. Set the vehicle on a level surface and chockthe road wheels and select ‘P’ in the maingearbox.2. Disconnect the battery negative terminal andrelease the parking brake.From inside the vehicleRemove the four screws securing the liner inthe glove box.Lift out the liner to gain access to the bottomof the parking brake pivot bracket.Remove the cotter pin and clevis pin from theparking brake lever.Release the nut securing the parking brakeouter cable to the top of the parking brakemounting bracket. Slide the nut up the cableand push the inner and outer cable throughthe floor panel to the underside of thevehicle.From underneath the vehicle7. Remove the cotter pin, plain washer and clevispin securing the adjustment link to the brakedrum actuating lever.Fit new cable10.11.12.13.14.15.16.1718.Feed the parking brake cable assemblythrough the floor opening and secure theouter cable in position with the retaining nut.Secure the cable to the parking brake lever,using a new cotter pin.Secure the outer cable into the ‘P’ clamp.Position the outer cable into the retainingbracket bolted to the side of the transfergearbox and loosely secure in position withthe two outer cable lock nuts.Reconnect the outer cable to the brake drumactuating lever. Fit the clevis’pin, plain washerand new cotter pin.Rotate the brake drum adjuster clockwise untilthe brake shoes are fully expanded against thedrum. .Tighten the two brake cable outer lock nuts tosecure the cable to its mounting bracket.Apply the parking brake, and loosen the brakedrum adjuster until the parking brake leverfully operates the brake shoes on the secondor third notch of the parking brake ratchet.Refit the glove box liner.!..,,.,.’ I..3 0REVISED: JULY 88


,a,i’‘,,’BRAKE SYSTEM-(Vehicles fitted with Lucas Cirlingmaster cylinder and servo)DescriptionThe hydraulic braking system fitted to Range Roversis the dual line type, incorporating primary andsecondary hydraulic circuits.NOTE: References made to primary or secondarydo not imply main service brakes or emergencybrakes but denote hydraulic line identification.The brake pedal is connected to a vacuum assistedmechanical servo which in turn operates a tandemmaster cylinder. The front disc brake calipers eachhouse four pistons, the upper pistons are fed bythe primary hydraulic circuit, the lower pistons bythe secondary hydraulic circuit. The rear disc brakecalipers each house two pistons, these are fed bythe secondary hydraulic circuit via a pressurereducing valve.A brake fluid level switch is incorporated into thereservoir cap assembly, the switch having detectedeither low or sudden fluid loss will immediatelyilluminate a warning light in the instrumentbinnacle.The brake fluid reservoir is divided, the sectionclosest to the servo feeds the primary circuit andthe section furthest from the servo feeds thesecondary circuit. Under normal operatingconditions both the primary and secondary circuitsoperate simultaneously on brake pedal application.In the event of a failure in the primary circuit thesecondary circuit will still function and operate frontand rear calipers. Alternatively, if the secondarycircuit fails the primary circuit will still function andoperate the lower pistons in the front calipers,allowances should be made and vehicle speedadjusted accordingly to allow for the lack of fullbraking efficiency.If the servo should fail, both hydraulic circuits willstill function but would require greater pedal effortdue to the lack of vacuum assistance.The hand operated parking brake acts on a brakedrum at the rear of the transfer gearbox and iscompletely independant of the hydraulic circuits.Brake pad wear sensors are incorporated in thefront and rear right hand side inboard brake pads.The sensors will illuminate a brake pad wearwarning light in the instrument binnacle, when padthickness has been reduced to approximately 3mm(0.11&i in).CAUTION: THOROUGHLY CLEAN ALL BRAKECALIPERS, PIPES AND FllTlNGS BEFORECOMMENCING WORK ON ANY PART OF THEBRAKE SYSTEM. FAILURE TO DO SO COULDCAUSE FOREIGN MAlTER TO ENTER THE SYSTEMAND CAUSE DAMAGE TO SEALS AND PISTONSWHICH WILL SERIOUSLY IMPAIR THEEFFICIENCY OF THE BRAKE SYSTEM.To ensure the brake system efficiency is notimpaired the following warnings must beadhered to :-DO NOT use any petroleum (gasoline) basedcleaning fluids or any proprietary fluidscontaining petroleum (gasoline). The preferedfluids are clear methylated spirits, industrial .alcohol or a proprietary aerosol brake cleaningproduct.DO NOT use brake fluid previously bled fromthe system.DO NOT use old or stored brake fluid.ENSURE that only new fluid is used and that it istaken from a sealed container.DO NOT flush the brake system with any fluidother than the recommended brake fluid.The brake system should be drained and flushedat the recommended service intervals.Continued-LUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: IULY 87 31


PRIMARY HYDRAULIC CIRCUITSECONDARY HYDRAULICCIRCUIT. ..$.: pRR2226M.-.‘I.;......:32 ’ LUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: JULY 87: . .


n-. . . ._.RR2222EBRAKE PIPE LAYOUTLeft hand driveHOSESI. Front left hand flexible hoses.2. Front right hand flexible hoses.3. Intermediate flexible hose.PIPES4. Feed to front left hand hose connector.5. Feed to front right hand hose connector.6. Feed to front left hand caliper.7. Feed to front right hand caliper.8. Feed to rear left hand caliper.9. Feed to rear right hand caliper.10. Feed to two way connector.11. Feed to intermediate hose.12. Two way connector.13. Three way connector.14. Pressure reducing valve.ContinuedLUCAS CIRLING MASTER CYLINDER AND SERVO - ADDITION: JULY 87 33. “....: :.


1987 RANGEROVERWARNING: Some components on the vehiclesuch as gaskets and friction surfaces (brakelinings, clutch discs, or automatic transmissionbrake bands), may contain asbestos. Inhalingasbestos dust is dangerous to your health andthe following essential precautions must beobserved :-NOTE: When bleeding the system commencewith the caliper furthest from the mastercylinder and bleed from the screw on the sameside as the fluid inlet pipes, then close the screwand bleed from the screw on the opposite sideof the same caliper. Tighten the bleed screws tothe correct torque value. See section 06* Work out of doors or in a well ventilatedarea and wear a protective mask.* Dust found on the vehicle or producedduring work on the vehicle should beremoved by vacuuming or by using a welldampened cloth and not by blowing. 2.* Dust waste should be dampened, placed in asealed container and marked to ensure safedisposal.1 If any cutting, drilling etc, is attempted onmaterials containing asbestos the itemshould be dampened and only hand tools orlow speed power tools used.BRAKESBleeding1.3.4.5.Fill-the fluid reservoir with the correct grade offluid, see section 09 lubricants and fluids.NOTE: The correct fluid level must bemaintained throughout the procedure ofbleeding.Connect a bleed hose to the bleed screw onthe rear caliper furthest from the mastercylinder.Submerge the free end of the bleed hose in acontainer of clean brake fluid.Loosen the bleed screw l/2-3/4 of a turn.Operate the brake pedal fully and allow toreturn.NOTE: Allow at least five seconds to elapsewith the foot right off the pedal to ensurethat the pistons fully return beforeoperating the pedal again.Bleed 6.The hydraulic system comprises two completelyindependent circuits. The rear calipers and thelower pistons in the front calipers form thesecondary circuit, while the upper pistons in thefront calipers form the primary circuit, The followingprocedure covers bleeding the complete system,but it is permissible to bleed one circuit only ifdisconnections are limited to that circuit.7.Repeat 5 until fluid clear of air bubblesappears in the container, then keeping thepedal fully depressed, tighten the bleed screw.Remove the bleed hose and replace the dustcap on the bleed screw.Bleeding will be assisted if the engine is run or avacuum supply is connected to the servo.WARNING: IF THE ENGINE IS RUNNING DURINGTHE BRAKE BLEEDING PROCESS ENSURE THATNEUTRAL OR PARK IS SELECTED IN THE MAINGEARBOX AND THAT THE PARKING BRAKE ISAPPLIED.When bleeding any part of the secondary circuit,almost full brake pedal travel is available. Whenbleeding the primary circuit only, brake pedal travelwill be restricted to approximately half.. . . . .. . ‘\’34 LUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: IULY 87.’


‘.;;;z; 1987BRAKES 70 \:,’ .,’‘.,.,: .:I8.9.10.11.12.13.Repeat 1 to 7 fr the other rear caliper.Remove the front wheel on the side furthestfrom the master cylinder.Connect a bleed hose to the primary bleedscrew on the front caliper furthest from themaster cylinder.Connect a bleed hose to the secondary bleedscrew on the same side of the caliper as theprimary screw.Repeat 3 to 7 for the front caliper, bleedingfrom the two screws simultaneously.Connect a bleed hose to the other screw onthe front caliper furthest from the mastercylinder.MASTER CYLINDER - Lucas Girling- Type 25.4mm AS/ASRemove, overhaul and refitRemoving1.2.3.4.5.6.Disconnect the battery negative terminal.Place a suitable container under the mastercylinder to catch any brake fluid which mayseep from the cylinder when the brake pipesare disconnected from the outlet ports.Thoroughly clean the immediate area aroundall outlet ports. Remove each of the brakepipes from the master cylinder in turn, sealingeach pipe and outlet port with suitable plugsas they are disconnected, to prevent ingress offoreign matter and excessive fluid loss.Disconnect the electrical plug from the lowfluid switch located on the reservoir cap.Remove the two nuts securing the mastercylinder to the servo unit remove also thespring and plain washers.Detach the the master cylinder from the servo,remove the reservoir cap and drain the brakefluid into a suitable container.614.15.16.Repeat 3 to 7 for the second secondary screwon the front caliper.Refit the front wheel.Repeat 9 to 15 for the front caliper nearest themaster cylinder.6WARNING: Do not use brake fluid previouslydrained or bled from the system. Carefullydispose of unwanted fluid, if stored in a sealedcontainer, ensure that the container is markedUSED BRAKE FLUID.ContinuedLUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: JULY 87IREVISED: SEPT. 87 35


RANGElg8’ ROVERRR2237MOverhaulWARNING: Use only clear methylated spirit orunused brake fluid to clean any part of thebrake system. DO NOT use petrol, kerosene orother mineral based fluids.10. Ease the reservoir out of the master cylindertaking care to ensure that the two outlet portson the bottom of the reservoir do notbecome damaged during this process.7.8.9.Before commencing the overhaul procedurethoroughly clean the master cylinder andinspect the outer surfaces for damage andcondition, renew the complete assembly ifnecessary.Using two soft jaws, one either side of themaster cylinder flange, clamp the flange in asuitable vice. Remove the water ingress ‘0’ring seal from the master cylinder to servoflange and discard.Grip the outside of the transfer housing withasuitable pair of pliers, carefully pull, whileworking the pliers in a backwards and forwardsrocking motion to ease the housing off themaster cylinder, discard the housing andvacuum seal..., .\I‘.\I!RR2244M36LUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: ]UlY 87/REVISED: SEPT. 87


Withdraw the two reservoir seals from themaster cylinder inlet ports the seals aredifferent and should be noted forassembly,discard both of the seals.Remove the retaining ring and ‘0’ ring sealfrom the machined outer surface of the mastercylinder, discard both the seal and retainingring.Remove the guide ring from the mouth of themaster cylinder which supports the primaryplunger assembly and place to one side, thiscomponent is not part of the master cylinderservice kit and is to be refitted on assembly ofthe unit.Pull the primary plunger assembly out of themaster cylinder. /NOTE: The primary plunger assemblycannot be broken down any further and isserviced as a complete unit. Discard theassembly.17. Clean all parts with Cirling cleaning fluid orunused brake fluid and place the cleaned partsonto a clean sheet of paper. Inspect thecylinder bore and plungers for signs ofcorrosion, ridges and score marks. Providedthe working surfaces are in perfect condition,new seals from a Cirling Service repair kit maybe used.Renewing secondary plunger seals18 Remove from the following components fromthe secondary plunger and discard:RR2238M15.16.”The secondary plunger assembly will remain atthe bottom of the master cylinder bore, theplunger can be easily expelled by tapping theassembly on a piece of wood until the plungerappears at the cylinder mouth, carefully pullthe plunger out of the master cylinder.If the swirl tube was not expelled at the sametime as the secondary plunger, repeat theabove operation to expel it from the bottomof the master cylinder bore and discard.NOTE: A small screwdriver with the endrounded off and polished is required toremove the ‘L’ seal. DO NOT damagesecondary plunger.(A) Springs(B) Seal retainer(C) Recuperating seal (primary cup)(D) Washer(E) ‘L’ sealRR2233MAContinuedLUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: JULY 87 3 7I.:..


RANGE“* ROVER. . . ..>.:‘.,:,:;.,‘...‘/..*. 1:(.’ .‘.. .:.i:,. ..’X‘.,_ .’::..*. . . +*KEY TO MASTER CYLINDER:,’ ,_:.,’*’.’1. Water ingress seal2. Transfer housing3. Vacuum seal4. Guide ring5. Retaining ring6. ‘0’ ring seal7. Primary plunger assembly8. ‘L’ seal9. Secondary plunger10. WasherIl. Recuperating seal (primary cup)12. Seal retainer13. Springs (2 off)14. Swirl tubeIS. Master cylinder body16. Reservoir seals17. Reservoir18. Low fluid level switch and cap. .NOTE: Thoroughly check that no debris of any description is lodged in any of the fluid passagewaysand drillings. If debris is found, carefully remove, re-clean the cylinder and re-check... -,,.I.’..:. , :‘,:.:... ~‘,38 ’ LUCAS GIRLING MASTER CYLINDER AND SERVO - ADDITION: JULY 87::


.’Coat the new seals in unused brake fluid andRR223BM.:ASSEMBLING THE MASTER CYLINDER‘. :.,,r‘1.firstly fit the ‘L’ seal to the plunger.Fit the washer followed by the recuperatingseal. Fit the seal retainer and springs, ensurethe springs are correctly seated.CAUTION: It is important that the followinginstructions are carried out precisely, otherwisedamage could be caused to the new seals wheninserting the plungers into the cylinder bore.Generous amounts of new brake fluid should beused to lubricate the the parts during assembly.Never use old fluid or any other form ofcleaning and lubricating material. Cleanlinessthroughout is essential.21. Fit the new swirl tube to the bottom of thecylinder bore.22. Lubricate the secondary plunger and cylinderbore. Offer the plunger assembly to thecylinder until the recuperation seal is restingcentrally in the mouth of the bore. Gentlyintroduce the plunger with a circular rockingmotion, as illustrated. Ensuring that the sealdoes not become trapped, ease the seal intothe bore and slowly push the plunger downthe bore in one continuous movement.RR2240M23. Fit the primary plunger assembly using thesame method as for the secondary plunger,push the plunger down the bore.24. Fit the original guide ring to support theprimary plunger.25. Coat a new ‘0’ ring with brake fluid and fit toits respective groove on the outer locationsurface of the master cylinder.NOTE: The ‘0’ ring should not be rolleddown the outer location surface of themaster cylinder but should be slightlystretched and eased down the cylinder andinto its groove. DO NOT OVER STRETCHTHE SEAL.26. Fit a new retaining ring on the outer surface ofthe master cylinder ensuring that the serrationsof the ring are facing the mounting flange.27. Fit the two new reservoir seals in theirrespective ports.28. Fit a new vacuum seal to either the primaryplunger or to the bottom of the transferhousing bore, open face of the seal towardsthe primary plunger guide ring.29. Lubricate the vacuum seal with brake fluid, fitthe transfer housing to the master cylinder,push the housing fully upto the cylindermounting flange, DO NOT ADJUST THETRANSFER HOUSING AFTER FITTING.30. Lubricate a new water ingress seal with brakefluid, slightly stretch the seal and ease it downthe housing until the seal is in the correctposition between the housing and flange.31. Roll the reservoir into the top of the mastercylrnder. reversing the procedure described ininstruction 10.LUCAS GIRLINC MASTER CYLINDER AND SERVO - ADDITION: JULY 87 39


1987 RANGEROVER32. Fit the master cylinder to the servo fit theplain and spring washers and secure inposition with the two nuts. Tighten to thespecified Torque value- see section 06.33. Fit the brake pipes to the master cylinder andtighten to the specified Torque value- seesection 0634. Top-up the master cylinder with the correctgrade of brake fluid (see section 09) bleed thebrake systems.SERVO ASSEMBLY . .IRemove and refitNOTE: Other than replacing the filter,non-return valve and grommet, the servo isnot a serviceable component, in the eventof failure or damage fit a new unit.RemovingWARNING: Do not use brake fluidpreviously drained or bled from the system.Carefully dispose of unwanted fluid, ifstored in a sealed container, ensure thatthe container is marked USED BRAKE FLUID.35. Fit the cap with combined low level fluidswitch and reconnect the electrical lead.Re-connect the battery.1.2.3.4.5.6.7.Disconnect the battery negative terminal.Disconnect the electrical plug to the low fluidlevel swatch.Thoroughly clean the immediate area aroundall master cylinder outlet ports. Remove eachof the brake pipes from the master cylinder inturn, sealing each pipe and outlet port as theyare disconnected with suitable plugs, toprevent ingress of foreign matter andexcessive fluid loss.Disconnect the vacuum supply hose to theseTv0.From inside the vehicle remove the lower dashpanel to gain access to the spring clipsecuring the servo push rod to the brakepedal assembly.Release the spring clip and remove the clevispin securing the servo push rod to the brakepedal.Remove the two nuts and plain washerssecuring the servo to the bulkhead pedal box.. I,RR2232E II I40 LUCAS GIRLINC MASTER CYLINDER AND SERVO - ADDITION: IULY 87


8. From within the engine compartment withdrawthe servo and master cylinder assembly.9. Remove the cap from the reservoir and drainthe brake fluid into a suitable container. If themaster cylinder assembly can be kepthorizontal it will not be necessary to drain thefluid.WARNING: Do not use brake fluid previouslydrained or bled from the system. Carefullydispose of unwanted fluid, if stored in a sealedcontainer, ensure that the container is markedUSED BRAKE FLUID.IO. Detach the spacer from the pedal boxmounting face of the servo, it is important thatthe spacer is fitted to the mounting face ofthe new servo to ensure that stringent pedalto servo operating dimensions are maintained.16.17.18.19.20.21.22.Fit the plain washers and secure the servo withthe two nuts. Tighten the nuts to the specifiedTorque value-see section 06.Refit the lower dash panel.Fit the master cylinder to the servo, refit theplain and spring washers and secure themaster cylinder to the servo with the two nuts.Tighten the nuts to the specified torque-seesection 06 -Torque values.Remove the sealing plugs, fitted to the mastercylinder outlet ports during the removalprocedure and refit the brake pipes to theirrespective ports. Tighten the brake pipes tothe correct torque-see section 06-Torquevalues.Refit the vacuum supply hose.Fill the master cylinder to between the ‘MAX’and ‘MINI level markings with the correctgrade of brake fluid-see section 09.Bleed the brake systems.7RR2233M-,..-- 11. If a new servo is being fitted it will benecessary to remove the master cylinder fromthe existing servo and refitted to the new unit.Refitting::12. Fit the spacer previously removed from the oldservo, to’the new servo.13. Fit the servo to the pedal box assembly.14. From inside the vehicle lightly grease thebrake pedal around the area that the servopush rod pivots.15. Fit the push rod to the brake pedal and securein position with the clevis pin and clip., ‘,,,.,‘.::.‘( ,.; ; :LUCAS GIRLINC MASTER CYLINDER AND SERVO - ADDITION: JULY 87 REVISED: MAY 89 41‘.i:’..:.,:.‘.,


RANGE“*’ ROVERPEDAL ASSEMBLYRemove, overhaul and refitRemove1. Disconnect the battery negative terminal.2. From inside the vehicle remove the lower dashpanel to gain access to the pedal assembly.3. Release the spring clip ad remove the clevispin securing the servo push rod to the brakepedal.4. Remove the circlip from the ‘D’ shaped end ofthe pedal shaft.5. Remove the pedal shaft from the pedalassembly and withdraw the pedal from thepedal box.6. Remove the return spring from the pedal.Refitting10.11.12.13.Fit the return spring to the pedal.Fit the pedal to the pedal box assembly andrefit the pedal shaft.Secure the pedal assembly in position with anew circlip.Lightly grease the servo push rod and securein position with the clevis pin and clip.Refit the lower dash panel and reconnect thebattery.Overhaul7.8.9.Remove the bushes from the pedal pivot tube.Press new bushes into the pedal pivot tube. Ifnecessary ream out the bushes to 15.87mmplus O.OSmm t.625 in plus .002in).Lightly grease the bushes.RR2220EI ICI4 2 LUCAS CIRLING MASTER CYLINDER AND SERVO - ADDITION: ]ULY 87


,’PARKING BRAKE CABLERemove and refitRemovingInside the vehicle1.2.3.4.5.6.7Set the vehicle on level ground or place on ahoist, select ‘P’ in main gearbox. Disconnectthe battery negative terminal.Chock the road wheels.Fully release the parkbrake lever.Remove the four retainrng screws and lift outthe glove box liner to gain access to thebottom of the parkbrake lever.Remove the cotter pin and withdraw the cfevispin and washer securing the cable to theparkbrake lever.Remove the clip from above the adjustmentthumbwheel, push the inner and outer cableto the underside of the vehicle.Pull the thumbwheel from the outer sleeve.RR241 1EwI I, Withdraw the cable.Fit new cable12. Reverse instructions 5 to 11 when fitting anew cable.Adjust parkbrake1314Ensure that the parkbrake lever is fullyreleased.From underneath the vehicle, rotate theadjuster on the brake drum back plateclockwise until the brake shoes are fullyexpanded against the brake drum.‘..Underneath the vehicle8. Remove the cotter pin and withdraw the clevispin and washer.9. Detach the retaining clip securing the outercable to the support bracket located on thefront cover of the transfer gearbox.10. Release the cable from the ‘P’ clip located onthe left hand side of the transfer gearbox.IContinuedADDITION: SEPT. 88 / REVISED: DEC. 88 43


:.:.l-lRANGE70 BRAKES “*’ ROVER15. Back off the adjuster until the drum is free torotate.16. Rotate the adjustment thumbwheel below theparkbrake lever until the parking brake is fullyoperational on the third notch of the ratchet.NOTE: The parking brake adjustmentthumbwheel must only be used for initialsetting and to compensate for cable stretch,it must not be used to take up brake shoewear, which must continue to be adjustedat the brake drum.., ,’.:‘.,’17. Operate the parkbrake once or twice to settlethe brake shoes, recheck that the parkbrake isfully operational on the third notch of theratchet. Re - adjust as necessary.18. Refit the glove box liner.19. Reconnect the battery and remove the wheelchocks..,.:; 4 4_:.ADDITION: SEPT. 88 / REVISED: DEC. 88 ::


.I,...CLQMON DEWANDRE - WABCO POWERASSISTED HYDRAULIC BRAKE SYSTEM WITHINTEGRATED ANTI-LOCK BRAKE SYSTEM - ABS1NTRODVCTlONThe purpose of ABS is to prevent the vehiclewheels locking during brake application, thusmaintaining vehicle steerability and stability. Thisallows the vehicle to be steered whilst the brakesare applied, even under emergency conditions, andto avoid obstacles where there is sufficient space toredirect the vehicle.WARNING: ABS IS AN AID TO RETAININGSTEERING CONTROL AND STABILITY WHILEBRAKING.CAUTION: THOROUGHLY CLEAN ALL BRAKECOMPONENTS, CALIPERS, PIPES AND FllTlNGSBEFORE COMMENCING WORK ON THE BRAKESYSTEM. FAILURE TO DO SO COULD CAUSEFOREIGN MATTER TO ENTER THE SYSTEM ANDDAMAGE SEALS AND PISTONS, WHICH WILLSERIOUSLY IMPAIR BRAKE SYSTEM EFFICIENCY.WARNING:DO NOT use brake fluid previously bled fromthe system.DO NOT use old or stored brake fluid.ENSURE that only new fluid is used and that it istaken from a clean sealed container.:- ABS CANNOT DEFY THE NATURAL LAWS OF DO NOT flush the brake system with any fluidPHYSICS ACTING ON THE VEHICLE.other than the recommended brake fluid.‘.- ABS WILL NOT PREVENT ACCIDENTSRESULTING FROM EXCESSIVE CORNERINGSPEEDS, FOLLOWING ANOTHER VEHICLE TOOCLOSELY OR AQUAPLANING, I.E. WHERE ALAYER OF WATER PREVENTS ADEQUATECONTACT BETWEEN THE TYRE AND ROADSURFACE.- THE ADDITIONAL CONTROL PROVIDED BY ABSMUST NEVER BE EXPLOITED IN A DANGEROUSOR RECKLESS MANNER WHICH COULDJEOPARDISE THE SAFETY OF THE DRIVER OROTHER ROAD USERS.The brake system must be drained and flushedat the recommended service intervals.Fluid pressures of 170 bar (2466 psi) areproduced by the hydraulic pump. It is essentialthat the procedure for depressurising the systemis carried out where instructed.COMPONENT DESCRIPTION- Numbers refer to RR2705Hydraulic booster unit (1).a., ,.:.:‘. .’.”T”,‘. :SYSTEM DESCRIPTIONThe brake system is hydraulically power assistedwith an integrated, electronically controlled fourchannel anti-lock brake system (ABS).The use of a power assisted brake system means‘that during brake application, additional hydraulicenergy is provided by a hydraulic power unit.This hydraulic power unit consists of an electricallydriven pump and an accumulator which storeshydraulic energy in readiness for brake application.A pressure switch controls the hydraulic pump tomaintain fluid pressure in the accumulator.The hydraulic system comprises two completelyindependent circuits. The rear calipers and upperpistons of the front calipers form the POWERCIRCUIT The lower pistons in the front calipersform the COMBINED POWER/HYDROSTATICCIRCUIT ,Mounted in the same position as the conventionalmaster cylinder/servo unit, the booster unit containsthe following components: Fluid reservoir, powervalve, master cylinder, isolating valve, ABS solenoidcontrol valves, semo cylinder.NOTE: The hydraulic booster unit is not aserviceable item, if internal failure occurs a newunit must be fitted. The fluid reservoir and itsseals may be changed in the event of damage.Extreme care must be taken when changing sealsto avoid ingress of debris.Fluid reservoir (1 .l).:Mounted on top of the booster unit, the plasticreservoir is subdivided internally to provide separatecapacity for the brake fluid used in the hydrostaticand power circuits. A central tube incorporates afilter and a low fluid warning level switch..:.: :‘:. 1.:.’.‘.’ ‘,. ::.:.::ADDITION: SEPT. 89 45


‘IHYDRAULIC COMPONENTSnI--------7KANGtilggo ROVER,,:.:;‘.. .: :‘.I.’‘:I:.,‘,‘,.’1, (1::.:: .,:.;._ 1..::.+.:.5..I’,. .,.::.:.‘.A‘.::,:.:: . . . . ,:.‘:_.,. . . . ,.*.FAAm B-Key to diagramC - D - E---c -Hydrostatic (master cylinder) circuitD - Combined hydrostatic/power circuitE - Component enclosureA - Fluid feed/returnB - Power circuit46 ’ ADDITION: SEPT. 89‘.


!’Power valve (1.2)Hydraulic power unit (2): The power valve is an extension of the mastercylinder, it controls fluid pressure in the powercircuit in direct proportion to pressure in the mastercylinder. The power valve is of spool valve design.Master cylinder (1.3)Operation of the master cylinder displaces a volumeof brake fluid into the servo cylinders and increasesfluid pressure. Piston movement inside the mastercylinder will also activate the power valve. A tiltvalve is incorporated to supply fluid to the mastercylinder from the reservoir connection.The hydraulic power unit comprises an electricallydriven pump and a pressure switch. The pressureswitch incorporates three electro-mechanicalswitches: one for the pump, another, at a differentpresure setting, to illuminate the pressure warninglight, The latter switch plus the third switch informthe ECU of low pressure and that ABS functionshould cease whilst pressure remains low.The pump also incorporates a non-return valve, alow pressure inlet filter, and a pressure relief valveto protect the system.Accumulator (3):tsolating valve (1.4)The isolating valve consists of two solenoid valvescontrolling fluid inlet and outlet. Their function is todisconnect the master cylinder from the servocylinder and to connect the servo cylinder to thereservoir return during ABS function.ABS solenoid control valves - 8 off (1.5)The diaphragm accumulator is precharged withnitrogen, its function IS to store hydraulic energy.Pressure conscious reducing valve (PCRV) (4)The PCRV valve is located between the power valveand the ABS solenoid valves for the rear axle. Itsfunction is to limit the brake pressure to the rearaxle.,”Each pair, comprising inlet and outlet solenoidvalves, controls ABS braking to each wheel. Inresponse to signals from the ECU, the valvesdecrease, hold or increase brake pressure accordingto the need to retain wheel rotation and obtainoptimum braking. The solenoid valves are designedto respond rapidly to ECU signals.Servo cylinders - 2 off (1.6)The servo cylinders have four functions.1. To provide combined energy from both thehydrostatic and the power circuit to the brakecalipers.2. To provide ‘brake feel’ at the brake pedal.3. To provide hydrostatic (master cylinder)braking through the servo cylinder to thecalipers in the event of no power circuitpressure to the servo cylinder.4. To provide braking from both the powercircuit and from hydrostatic fluid remaining inthe servo cylinder, in the event of nohydrostatic circuit pressure from the mastercylinder.Brake calipers - front - (5) rear - (6)NOTE: To identify the separate hydraulic circuits,they are referred to as Hydrostatic and Powercircuits.Power circuit - The rear calipers and the upperpistons in the front calipers form one circuit,supplied by direct hydraulic power from the powervalve.Hydrostatic circuit - The lower pistons in the frontcalipers form the other circuit, supplied withhydraulic energy from the servo cylinderscomprising a combination of master cylinderpressure and direct hydraulic power.I‘.‘...‘, ..*:’ADDITION: SEPT. 89 / REVISED: MARCH 90 47


RANGE70 BRAKES “‘O ROVER:..RR2708MLOCATION OF COMPONENTS (RR2706M)1. Hydraulic booster unit.2. Power unit - hydraulic pump.3. Accumulator.4. Electronic control unit (ECU), relays and fuses.5. Rear sensors/exciter rings.6. Front sensors/exciter rings.Electronic control unit - ECUABS operation is controlled by the ECU locatedunder the left hand front seat, and earthed to thecentre tunnel.The ECU is connected to the ABS harness by a 35way connector.The ECU is a non-serviceable- item, it must bereplaced if failure occurs.Sensors, exciter rings - 4 off.’.‘:‘.‘:A sensor is mounted at each wheel, sensing a 60tooth exciter ring. When the vehicle’ is in motionthe inductive sensors send signals to the ECU. Thefront exciter ring is fitted to the outside diameter ofthe constant velocity joint in each front hub. Therear exciter ring is bolted to the rear of each brakedisc bell.I. ‘..,/48 ADDITION: SEPT. 89 / REVISED: MARCH 90. . :


RR2714MBrake pipe layout - left hand driveHOSES1. Front left hand flexible hoses.2. Front right hand flexible hoses.3. Left hand intermediate hose4. Right hand intermediate hosePIPES.i5. Feed to front left hand hose connector.6. Feed to front right hand hose connector.7. Feed to front left hand caliper.8. Feed to front right hand caliper.9. Feed to left hand intermediate hose.10. Feed to right hand intermediate hose.11. Two way connector.12. Feed to rear left hand caliper.13. Feed to rear right hand caliper.ADDITION: SEPT. 89 49


1990 RANGEROVERWARNING LIGHTSABS warning light - (amber) - 2. ..’‘,,. ..’Brake fluid pressure/level and parking brakewarning light - (red) - 1The warning light situated in the instrumentbinnacle indicates that there is insufficient pressurein the system and/or the fluid level is too low. Thelight will illuminate when ignition is switched ON aspart of initial bulb check, and when the parkingbrake is applied.If the pressure in the hydraulic system is lower thanthe cut-in pressure for the warning light, the lightwill illuminate. When the light is on the hydraulicpump will start. Therefore, if the light remainsilluminated after bulb check and releasinghandbrake, DO NOT drive the vehicle until the lightextinguishes.WARNING: IF THE LIGHT ILLUMINATES WHILETHE VEHICLE IS IN MOTION, THE FAULT MUSTBE INVESTIGATED IMMEDIATELY. BRAKING WILLBE AVAILABLE AFFER A LOSS OF PRESSURE, BUTGREATER FORCE WILL BE REQUIRED AT THEPEDAL TO SLOW THE VEHICLE.WARNING: Power assisted braking is notavailable if the ignition is switched off. Anincrease in effort at the pedal will be required toapply the brakes.The ABS warning light situated in the instrumentbinnacle indicates that there is a failure in the ABSsystem. The light will illuminate when the ignition isswitched ON , and will extinguish when the vehicleexceeds 7 km/h (5 mph) This indicates that thesystem sell monitoring check was successful, andthe system performs correctly.If the light remains on or subsequently illuminateswith the ignition ON a fault in the ABS system isindicated. The self monitoring procedure isrepeated frequently while the ignition is ON . If afault is detected during self monitoring, the lightwill illuminate indicating that one or more wheelsare not under ABS control.WARNING: Reduced ABS control is possible withthe ABS warning light illuminated depending onthe severity and type of fault. If both ABS andbrake failure warning lights are illuminated, lossof system pressure or hydraulic pump failure isindicated.IT IS ESSENTIAL THAT THE DRIVER HAS THE .‘.FAULT INVESTIGATED IMMEDIATELY.DRIVING THE VEHICLEWARNING: On surfaces which are soft and deep,for example deep powdery snow, sand or gravel,braking distance may be greater than with nonABS braking. In these conditions wheel lock andthe build up of snow or gravel under the wheelsmay be an aid to shorter stopping distance.However it is still an advantage to maintain thestability and manouevrability available with ABScontrol.1. Switch on ignition, the system willautomatically carry out its self test function.This will be felt as a slight movement in thebrake pedal and a short, rapid series of clicksindicating that the solenoid valves have beenchecked.‘.:,‘., ,‘,. .,,:.I. “:,..::.:: :.50 ADDITION: SEPT. 89


,,---;;;;; 1990B R A K E S2. Observe the warning lights, check that theparking brake/fluid pressure/level warning lightextinguishes after initial bulb check or whenthe parking brake is released, indicating thatpower assistance is available. Note that thetime taken to pressurise the system isapproximately 20 seconds.3. Start the vehicle and drive away, at 7 km/h (5mph) the ABS warning light must beextinguished - see Warning Lights.4. In road conditions where surface friction issufficient to slow or stop the vehicle withoutwheel lock, the ABS does not operate.5. In an emergency braking situation, if one ormore wheels begin to slow rapidly in relationto vehicle speed, ABS will detect the wheellocking tendency and will regulate the brakepressure to maintain wheel rotation.6. ABS operation will be felt as a vibrationthrough the pedal, at the same time thesolenoid cycling will be heard.NOTE: Constant pressure on the foot pedalwhilst ABS is operating is more effectivethan cadence braking. Do not pump thebrake pedal as this may reduce ABSefficiency and increase stopping distance.7. Downward travel of the pedal will also feelhard at the point at which ABS operates. littlefurther pedal travel is possible at this point,BUT, force on the pedal can be varied toinfluence braking while ABS retains control.BRAKE APPLlCATlON WITH PARTIAL FAILUREWARNING: IF A FAULT DEVELOPS IN THE BRAKESYSTEM IT IS ESSENTIAL THAT THE DRIVER HASTHE FAULT INVESTIGATED IMMEDIATELY.NOTE: If, during braking, a drastically reducedresistance is detected at the pedal and brakingeffectiveness is very much reduced, failure ofthe non-powered (master cylinder) portion ofthe system is indicated. When this occurs DONOT PUMP THE BRAKE PEDAL. Push the pedalthrough the free movement to obtain brakingeffort. For this reason it is essential that brakepedal travel is not obstructed by the addition ofitems such as extra footwell mats.1. When power assistance is not available, ABSbraking is not operative. Both warning lightsare illuminated. Braking effort is available fromthe master cylinder only. This results in longerpedal travel and greater pedal effort requiredto decelerate the vehicle.WARNING: FOOT PRESSURE ON THE PEDAL,USING MASTER CYLINDER ONLY, WILL NOTACHIEVE THE SAME DEGREE OF BRAKINGAS THAT AVAILABLE FROM POWERASSISTANCE.2. If the master cylinder fails, i.e. there isinsufficient fluid in the master cylinder tocreate pressure, braking to all four wheels isretained and ABS remains operative. The redwarning light will be illuminated if the cause ofthe master cylinder failure is a fluid leak andthe level in the master cylinder is low enoughto actuate the fluid level switch.WARNING: LONGER PEDAL TRAVEL ISREQUIRED, BUT POWER ASSISTED BRAKINGIS AVAILABLE AT A REDUCED EFFICIENCY.3. If brake failure occurs due to a fractured brakepipe between a servo unit and a wheel, therewill be no pressure in the reservoir. The fluidwarning light will be illuminated when thelevel in the master cylinder is low enough toactuate the fluid level switch. The mastercylinder and power valve w,ill operate as formaster cylinder failure. BUT, fluid from thepower circuit tiill push all the moving parts inthe servo cylinder associated with the failureto the limit of their travel. No pressurised fluidpasses to those brake pistons served by theservo cylinder, but all other pistons in frontand rear calipers will be supplied with directpressure from the power valve. The pistonsserved by the other servo cylinder retainbraking as fluid from the master cylinder isretained in the setvq cylinder not associatedwith the leakage.WARNING: BRAKE PEDAL TRAVEL WILL BEGREATER AND EXTRA PEDAL EFFORT WILLBE REQUIRED, ACCOMPANIED BY THEVEHICLE PULLING TO ONE SIDE.3 ‘.,ADDITION: SEPT. 89 / REVISED: MARCH 90 51


RANGElggo ROVERBooster harness plug wiring details1. Slate/yellow. 7. Slate/orange.2. Not used. 8. Slate/brown.3. Slate/white. 9. Slate/blue.4. Slate/green. IO. Slate/pink.5. Slate/black. I I. Slate/red.6. Slate/purple. 12. Not used.CIRCUIT DIAGRAM . RR2669MSTI.ST2.ST5.ABl.AB2.AB3.AB4.ABS.AB6.AB7.AB8.AB9.ABlO.ABll.ABI 2.AB13.AB14.AB15.AB16.AB17.AB18.AB19.AB20.BatteryTerminal postIgnition switch30 amp MAXI fuse - pump relayPump relay - blackHydraulic pumpHydraulic pump pressure cut off switchPump low pressure warning switchReservoir fluid level switchDiodeBrake fluid pressure/level warning lightABS warning light5 amp fuse, pump relay5 amp fuse, pin 9 ECU, diagnostic plug,brake light switchABS warning light relay - green25 amp fuse, valve relayValve relay - blackDiagnostic plugElectronic control unit (ECU)35 way connector to ECUBrakelight switchBrakelightsMultiplug to booster unitBooster unit components ABZl-25IV Inlet valveOV Outlet valve’AB21.AB22.AB23.AB24.AB25.AB26.AB27.AB28.AB29.AB30.Isolating valveFront left solenoid valvesFront right solenoid valvesRear left solenoid valvesRear right solenoid valvesSensor connectors (4)Front left sensorFront right sensorRear left sensorRear right sensora. 12 volts from fuse A5b. To bulb check unitCABLE COLOUR CODEB BlackG GreenU Blue S CreyN Brown0 OrangeK PinkP PurpleR RedW WhiteY YellowADDITION: SEPT. 69 / REVISED: MARCH 90


ABS - Circuit diagram--------3316351634173215, NB, BGNY) BWNU) BNBOm A B 3 0c m A 6 2 9’ m AB26 ”-ffvm A8274AB26:,’,.‘..----------4521226723241112SY) SW) SGSPSRsu, SK> SN) so) SB-( 1( 3( 4 ,


RANGE“‘O ROVERECU HARNESS PLUGECU harness plug wiring details - RR2690M18 1RR269m41. Brown/pink.2. Not used.3. Not used.4. Slate/yellow.5. Slate/white.6. Slate/red.7. Slate/blue8. Black/green9. Green/pink10. White/slate11. Slate/orange12. Slate/blackI 3. White/pink.14. Black/pink.15. Brown.16. Blackgreen.17. Black/brown.18. Black/white.19. Brown/pink.20. Not used.21. Slate/green.22. Slate/purple.23. Slate/pink.24. Slate/brown.25. Green/purple.26. Black/slate.27. Black.28. Not used29. Not used30. White/black.31. Black/yellow.32. Black/orange.33. Brown/black.34. Brown/blue.35. Brown/yellow.RELAYS AND FUSES:: ,..fIncorporated in the ABS electrical system are threerelays, located beneath the left hand front seatadjacent to the ABS ECU. Access to the relays isgained by removing the seat side trim.Relay and fuse identification (RR2816M)1. ABS warning light relay, green base - AB122. Valve relay, black base - AB143. Hydraulic pump relay, black base - A624. Hydraulic pump relay fuse, 5amp tan - ABlO5. Stop light switch, diagnostic plug, ECU pin 9fuse, 5 amp tan - ABll6. Valve relay fuse, 25 amp white - AB137. Hydraulic pump relay fuse 30 amp green MAXItype fuse - ABl;:,,. ‘,RR2818MInset shows fuse position on early 1990 vehicles.‘.’.,,,’ ‘,’,..’.: ,,‘:.,. .;:: :: :54 ADDITION: SEPT. 89 / REVISED: MARCH 90


GENERAL SERVICE INFORMATIONSYSTEM BLEED.I’:.” .,,‘,,.:,:: ,’‘,..: .,‘, ::,:NOTE: ABS components ARE NOT! serviceable.Replace components that are found to be faulty.Brake fluid precautionsWARNING: Do not allow brake fluid to comeinto contact with eyes or skin.CAUTION: Brake fluid can damage paintwork, ifspilled wash off immediately with plenty of cleanwater.CAUTION: Use only the correct brake fluid. If anassembly fluid is required use brake fluid. DoNOT use mineral oil, i.e. engine oil etc.Check/top up fluid level1. Park the vehicle on level ground.2. Turn ignition ON, to activate hydraulic pump.If pump does not activate depress brake pedalseveral times until it is heard to operate.3. When the pump stops, check that the level isbetween the ‘MINI and ‘MAX’ marks.4. If the level is below the ‘MINI mark top upfluid level to the ‘MAX’ mark on reservoir,using the correct fluid, - see Section 09,Lubricants and Fluids.EQUIPMENT: Bleed the system using a bleedtube and a clean bottle containing a smallamount of clean liquid.CAUTION: Clean all bleed screws, filler cap andconnections thoroughly using clean brake fluidonly. DO NOT USE MINERAL OIL I.E. ENGINE OILETC.MAINTAIN CLEANLINESS THROUGHOUT.NOTE: During bleed procedure the reservoirfluid level must not fall below the’MIN’ level.Regularly check level and keep topped up to‘MAX’ level.WARNING: Do not use previously used brakefluid. Ensure that only new fluid is used and thatit is taken from a clean sealed container.Carefully dispose of unwanted fluid in a sealedcontainer, marked USED BRAKE FLUID.I. Switch off ignition and depressurise thesystem. Ensure that ignition remains OFF untilinstruction 7.2. Fill the fluid reservoir with the specified fluidto the ‘MAX’ level.WARNING: Clean reservoir body and filler capbefore removing the cap. Use only fluid from asealed container.DO NOT OVER FILL THE RESERVOIRDEPRESSURISE..,I.’.‘),..‘. .,.C I,:,c’.‘,j:;;x‘..WARNING: Before bleeding the system orworking on any component in the brake systemthe following procedure MUST be carried out todepressurise the accumulator.Switch off ignition.Operate the brake pedal 30 times. Pedal travelwill increase slightly and reduced resistancewill be felt as pressure decreases.Wait for 60 seconds, press the brake pedalfour more times. This procedure will ensurethat all pressure is evacuated from the system.RR2721MNOTE: Time consumed in filling the boostermay be reduced by fitting a rubber bellowsunit to the filler neck, and using handpressure IO pressurise the reservoir. A sparebellows unit from the booster push rod issuitable for this purpose.Ensure the bellows unit is perfectly clean toavoid ioreign matter entering the system.Raising the rear of the vehicle will assist thefill procedure.,.y.. :.; ..:.3. Depress brake pedal slowly and progressivelyfive times, using full pedal stroke. Release thepedal for five to ten seconds, during this timeair bubbles will rise into the reservoir.ADDITION: SEPT. 89 / REVISED: MARCH 90 55


RANGElggo ROVER4. Repeat instruction 3. until some resistance isfelt. If no resistance is felt check that the clevispin is connected to the correct (UPPER) holein the brake pedal5. Bleed the four front caliper lower (hydrostatic)bleed screws in the conventional manner.Proceed in the order: outer bleed screw onthe driver’s side, opposite caliper outer bleedscrew, inner bleed screw, inner bled screwdriver’s side. Depress the brake pedal slowlyand progressively. Lock the bleed screw at thebottom of each stroke.6. Bleed the hydraulic pump - open the bleedscrew on the pump and allow fluid to flowuntil it is clear of air bubbles. Do not use thebleed bottle, use a clean absorbant cloth toprevent fluid spillage.7.8.9.12.13.14.Bleed the accumulator - ooen the bleedscrew. Switch on ignition, run pump for 3-4sets, switch off and repeat procedure until nofurther air bubbles enter bleed bottle. Switchoff ignition. Close the bleed screw.Bleed the two hydraulic booster bleed screws.Open one bleed screw, depress the brakepedal, switch on ignition, run pump until nofurther air bubbles enter the bleed bottle.Close booster bleed screw, switch off ignitionand release pedal. Repeat for other bleedscrew.Bleed power circuit at four calipers in turn.Depress pedal, open bleed screw, (upperbleed screw on front calipers). Switch onignition, run pump for 3-4 sets, switch off andrepeat procedure until no further air bubblesenter bleed bottle. Switch off ignition, closecaliper bleed screw, release pedal.Bleed master cylinder - switch ignition on.System pressure will increase until pump Cutsout. If pump does not cut out after runningfor 45 sets, check system for leaks.Bleed hydrostatic circuit calipers - open onefront lower caliper bleed screw. Actuate brakepedal several times, using only the lower twothirds of pedal travel, until no further airbubbles enter the bleed bottle. Stop actuationif fluid warning light comes on and allowpressure to build up.Close caliper bleed screw before releasingpedal, repeat for remaining three hydrostaticbleed screws.Check/top up reservoir fluid level - seeCheck/top up fluid level.Dry all connections, fully pressurise systemand check for leaks. If two full brakeapplications switch on pump, from fullycharged, rebleed system.CALIPERS - Front and rear,,.Refer to main workshop manual for caliper removeand refit. Use a recognised hose clamp, using theapproved procedure. If one caliper has beenremoved, and the use of a brake hose clamp’hasbeen effective in preventing fluid level falling belowthe minimum mark in the reservoir, bleed thebrakes as follows:Front caliper - bleed the front caliper at bothpower and hydrostatic circuits.Rear caliper - bleed the rear caliper.RR2722YNOTE: If the excessive fluid loss has occured, ..)bleed the complete brake system.56 ADDITION: SEPT. 89 / REVISED: MARCH 90


HYDRAULIC BOOSTER UNITRemove and refitRemovingCAUTION: Do not allow the booster unit to bedropped or rested on its front face. Damage tothe plastic tangs of the multiplug could occurwhich will require the fitting of a new boosterunit1. Disconnect battery negative lead, anddepressurise the system.2. Thoroughly clean the immediate area aroundthe booster unit outlet ports and electricalconnector.3. Disconnect the electrical multiplug from thebooster, and the connector to the low fluidswitch located in the reservoir cap. Removethe booster earth strap.4. Release the spring clip from the clevis pinsecuring the booster push rod to the brakepedal.5. Remove the four nuts and plain washerssecuring the booster unit to the bulkhead.6. Remove the booster unit.RefittingNOTE: New booster units are supplied in asealed pack marked with a ‘use by’ date. DONbT fit a booster if the date has elapsed, or ifthe pack is not sealed. DO NOT open the sealedpack until ready to fit the unit.7. Reverse the removal procedure, ensuringcorrect fitment of pipes to booster unit. Finallytighten booster fixings and pipes to thecorrect torque value. Ensure that the clevis pinis fitted into the UPPER of the two holes inthe brake pedal.8. Adjust the brake light switch, pull out theblack plunger, pull the brake pedal back fullyto reset the switch.9. Carry out the brake bleeding procedure.RESERVOIR SEALS - RenewWith the booster unit removed, and brake fluiddrained, is possible to fit new reservoir seals. Cleanthe unit thoroughly before removing the reservoir.RR2723M4. Remove brake pipes from booster unitincluding hydraulic pipes to the accumulatorand hydraulic power unit. Note that eachbooster outlet port is numbered, and eachbrake pipe is marked with the correspondingnumber to aid reassembly. Seal each pipe andoutlet port, as they are disconnected, withsuitable plugs, to prevent ingress of foreignmatter.3. Working inside the vehicle remove the lowerdash panel - see Body Section 76, mainworkshop manual.1. Remove the reservoir bracket securing boltadjacent to the low pressure suction hoseoutlet.2. Carefully ease the reservoir away from thebooster unit.RR2744M lil 4 /RR2725EI I I3. Remove the two seals located in the top ofthe booster unit. Avoid damage to the sealswhich could result in rubber particles enteringthe system.4. Fit new seals and refit the reservoir, tighteningthe securing bolt to the correct torque.5. Carry out the booster refitting procedure.ADDITION: SEPT. WREVISED: SEPT. 90 57


_.RANGE“‘O ROVER. ‘..HYDRAULIC POWER UNITACCUMULATOR -.:.). .. .Remove and refitRemovingWARNING: The accumulator is precharged withnitrogen. Handle with extreme caution. DO NOTpuncture or burn if disposal is necessary.1. Disconnect battery negative lead.2. Depressurise the system.3. Disconect the braided hose to theaccumulator, and the power unit multiplug.4. Loosen the hose clip and disconnect the lowpressure suction hose to the reservoir, clampthe hose to present fluid and ingress ofdebris.Remove and refitRemoving1. Disconnect battery negative lead.2. Depressurise the system.3. Remove the fluid inlet and outlet pipes fromthe accumulator..RR2720M5. Disconnect the pressure switch plug.6. Disconnect the power unit connector.7. Working from below the unit remove fournuts and plain washers.8. Remove the hydraulic power unit completewith mountings.Refit7. Reverse removal procedure. Check conditionof sealing washers on high pressure hose. Fitnew washers if necessary.8. Bleed system, finally top up fluid reservoir.4. Remove the wheelarch inner liner and removethe two nuts and plain washers securing theaccumulator. .I5. Remove accumulator.Refitting6. Reverse removal procedure. Check conditionof sealing washers on high pressure hose. Fitnew washers if necessary.7. Carry out brake bleed procedure.,.;’ :..:..-..-“.I :..:.. . . .,1 ,. i(. . .1‘. .’;:::.58 ADDITION: SEPT. gS/REVISED: SEPT. 90


.TYRESinspectionWhen the indicators appear in two or moreadjacent grooves, at three locations around thetyre, a new tyre must be fitted.Inspect tyres at weekly intervals to obtain maximumtyre life and performance and to ensure compliancewith legal requirements. Check for signs ofincorrect inflation and uneven wear, which mayindicate a need for balancing or front wheelalignment. Refer to the Tyre Wear Diagnosis Chartif the tyres have abnormal or uneven wear patterns.Check tyres at least weekly for cuts, abrasions,bulges and for objects embedded in the tread.More frequent inspections are recommended whenthe vehicle is regularly used in off road conditions.To assist tyre inspection, tread wear indicators aremoulded into the bottom of the tread grooves, asshown in the illustration below.NOTE: Do not attempt to interchange tyres, e.g.from front to rear, as tyre wear producescharacteristic patterns depending on theirposition. If such position is changed after wearhas occured, the performance of the tyre will beadversely affected.NOTE: Territorial vehicle regulations governingtyre wear MUST be adhered to.TyrepressuresMaximum tyre life and performance will beobtained only if tyres are maintained at thecorrect pressures.Tyre pressures must be checked at least once amonth and at least once a week, preferably daily, ifthe vehicle is used off road.The tyre inflation pressure is calculated to give thevehicle satisfactory ride and steering characteristicswithout compromising tyre tread life. Therecommended tyre pressures for all conditions aregiven in the General Specification Data Section andthe Owner’s Manual. A label attached to the insideedge of the driver’s door also provides tyrepressure information..-.RRzl45EWhen the tread has worn to a remaining depth of1.6 mm (1116 in) the indicators appear at thesurface as bars which connect the tread patternacross the width of the tread as shown in theillustration below.Always check tyre inflation pressures using anaccurate gauge and inflate tyres to therecommended pressures only.Check and adjust tyre pressures ONLY when thetyres are cold, vehicle parked for three hours ormore, or driven for less than 3.2 km (2 miles) atspeeds below 64 km/h (40 mph). Do not reduceinflation pressures if the tyres are hot or the vehiclehas been driven for more than 3.2 km (2 miles) atspeeds over 64 km/h (40. mph), as pressures canincrease by 0.41 bars (6 p.s.i) over cold inflationpressures.Check ALL tyre pressures including the spare. Refitthe valve caps as they form a positive seal and keepdust out of the valve.RA2146EREVISED: APR. 87 1. .


l-l 74 WHEELS AND TYRESRANGElg8’ ROVER1 234 4RR2133ENOTE: Radial ply tyres have a flexible sidewall,which produces a sidewall bulge making the tyreappear under-inflated. This is a normal conditionfor radial ply tyres. Do not attempt to reducethis bulge by over-inflating the tyre.1. Correct inflation.2. Under-inflation.3. Over-inflation.WHEELSRegularly check the condition of the wheels.Replace any wheel that is bent, cracked, dented orhas excessive runout.VALVESCheck the condition of the inflation valve. Replaceany valve that is worn, cracked, loose, or leaking air.4. Tread contact with road.:.t0’‘.\ t


;$$; 1987 WHEELS AND TYRES 74TYRE WEAR DIAGNOSIS •CONDITIONPOSSIBLE CAUSECURE:apid wear at thehoulderst wTyresunder-inflatedWorn suspension componentsi.e. ball joints, panhardrod bushes,steering damperInflate to correct pressureReplace worn componentsExcessive cornering speedsLapid wear at centrerf treadtTyres over-inflated , Inflate to correct pressurerVear at one shoulderToe out of adjustmentBent panhard rodBent shock absorberAdjust toe to correct figureCheck and replace worn ordamaged componentsBald spots or tyrecuppingWheel out of balanceExcessive radial runoutShock absorber wornBalance wheel and tyreassemblyCheck runout and replace tyreif necessaryReplace shockExcessive brakingTyre scalloped Toe out of adjustment Adjust toe to correct figureWorn suspension components Replace as necessaryExcessive cornering speeds?R2 136E•CAUTION: Thts diagnoses chart IS tor general guraance only anacause of abnormal tyre wear.. . . . I m .I I J J--- --* - ^^^^__m :,.. :,,,...-I, _.,Asues not rwxes54try IIILIYUI: 5.1iREVISED: APR. 87 3: ‘,.


WHEELS AND TYRESRANGElg8’ ROVERWHEELS AND TYRESBalanceNOTE: Before attempting to balance a wheel andtyre assembly clean all mud and dirt depositsfrom both inside and outside rims and removeexisting balance weights.Remove stones from the tyre tread in order toavoid operator injury during dynamic balancing andto obtain the correct balance.CAUTION: Use only the correct adhesive balanceweights to avoid damage to the aluminium ,, twheel rim. DO NOT attempt to use a steel wheelweight on an aluminium wheel.Static balance. WHEEL TRAMPInspect tyres for damage and correct tyre pressuresand balance according to the equipmentmanufacturer’sinstructions.-HEAVv SPOTADD BALANCE WEIQHTS HEREIRR2138ERR2130ECORRECTIVE WEIGHTS. .Static balance is the equal distribution of weight %,.Clean area of wheel rim and attach adhesive around the wheel. A statically unbalanced wheel willbalance weights in position shown. Cut through cause a bouncing action called wheel tramp. Thisrear face of weight strip to detach required weights. condition will eventually cause uneven tyre wear.NRC 7915RR2137E4 REVISED: APR. 87


WHEELS AND TYRES.’DynamicbalanceWhere possible always use the vehicle wheelretaining nuts to locate the wheel on the balancer,to avoid damaging the wheel. If this is not possible,the locating nuts must be of a similar pattern to theoriginal wheel nuts. The use of conical type wheelnuts for this purpose may damage the aluminiumalloy.CAUTION: It is essential that all wheel balancingis carried out off the vehicle. The use of on thevehicle balancing could cause componentdamage or personal injury and MUST NOT beattempted.GENERAL INFORMATIONIk-l- .-’ Il.ARR2140E CORRECTIVE WEIGHTSDynamic balance is the equal distribution of weighton each side of the centre line so that when thewheel spins there is no tendency for side to sidemovement. A dynamically unbalanced wheel willcause wheel shimmy.Off vehicle balancingBalance the wheel assembly referring to theequipment manufacturer’s instructions.It is essential that the wheel is located by thecentre hole NOT the stud holes. To ensure positivewheel location the diameter of the locating collaron the machine shaft must be 112.80 to 112.85 mm(4.441 to 4.443 in). This diameter will ensure thatthe collar fits correctly within the centre hole of thewheel.WARNING: THE RANGE ROVER IS A MULTI-PURPOSE VEHICLE AND AS SUCH THE WHEELSAND TYRES ARE DESiGNED FOR BOTH ON ANDOFF ROAD USAGE. ONLY THE WHEELS ANDTYRES SPECIFIED FOR USE ON THE VEHICLEMUST BE USED.The Range Rover is equipped with tubeless ‘S’ ratedradial tyres as standard equipment. The tyres are ofEuropean metric size and must not be confusedwith the “P” size metric tyres available in NorthAmerica.When tyre replacement is required the correct typeof radial-ply tyre must be used. Under nocircumstances must cross-ply or bias-belted tyres beused.Always use the same make and type of radial-plytyre throughout the vehicle.See Data section for tyre specification andpressures.The tyres are mounted on 7.0 inch wide by 16 inchdiameter cast aluminium alloy wheels. The wheelrim is of the asymmetric hump type incorporating asafety hump to improve location of the tyre bead inits seat. The surface has a paint finish covered witha clear polyurethane lacquer. Care must be takenwhen handling the wheel to avoid scratching orchipping the finish.CleaningWash the aluminium wheels using a suitable washand wax concentrate correctly diluted and rinsewith cold clear water. DO NOT use abrasives oraluminium wheel cleaners containing acid, as theywill destroy the lacquer finish.*,/ ,,._REVISED: MARCH 90 5j


WHEELS AND TYRESRANGE“*’ ROVER.,. : .’.:.‘).*. ,,‘. ..:.:,.;:,.TyrechangingUse only tyre changing equipment to mount ordemount tyres, following the equipmentmanufacturer’s instructions. DO NOT use handtools or tyre levers, as they may damage tyre beadsor the aluminium wheel rim.PuncturerepairRemove the punctured tyre from the wheel andrepair using a combination service plug andvulcanising patch. Always follow the manufacturer’sinstructions when using a puncture repair kit.Only punctures in the tread area are repairable, DONOT attempt to repair punctures in the tyreshoulders or sidewalls.Do not attempt to repair a tyre that has sustainedthe following damage: bulges or blisters, ply,separation, broken or cracked beads, wearindicators visible and punctures larger than l/4 inchdiameter.CAUTION: Do not use tyre sealants that areinjected through the valve stem to repairpunctured tyres as they may produce wheelcorrosion and tyre imbalance.Ahrminium wheel rim bead seats should be cleanedusing a non-abrasive cleaner to remove themounting lubricants and old rubber. Beforemounting or demounting a tyre, the bead areashould be well lubricated with a suitable tyrelubricant.Tyre fitting1. Install a new valve assembly.2. Ensure the wheel and tyre is adequatelylubricated.3. Mount the tyre in the normal manner. Inflatethe tyre and at the same time apply handpressure to the area around the valve to aidseating over the valve first.NOTE: Stop inflation immediately if the tyreseats opposite the valve, as this will resultin the valve being blocked by the tyrebeading, making further inflationimpossible, and carry out the followingprocedure.4. Deflate the tyre, unseat and rotate it aroundthe rim until the valve is in line with that partof the tyre which seated initially. This part ofthe beading having seated over the humppreviously will automatically seat first when thetyre is re-inflated.5. Inflate the tyre to seat the beads correctly,finally inflate to the correct pressure.WheelsRemove and refitWARNING: The parking brake acts on thetransmission, not the rear wheels, and may nothold the vehicle when jacking unless thefollowing procedure is used. If one front wheeland one rear wheel is raised no vehicle holdingor braking effect is possible. Wheels MUST bechocked in all circumstances.Always engage the differential lock. Note thatthe differential lock is only engaged if thewarning light is illuminated with the ignitionswitchedon.Apply the parking brake, select ‘P’ in the maingearbox and engage low gear in the transfer box.RemovingI. Loosen the five wheel nuts.2. Using a suitable floor jack raise the vehicle andplace on axle stands, see jacking procedure inMaintenance- Section 10.3. Remove the wheel nuts and carefully withdrawthe wheel over the studs.;“;,___,.,:;.6REVISED: MARCH 90


WHEELS AND TYRES 74 l-lRefitting Wheel stud4.5.6.7.8.9.Ensure that the retaining studs and nuts areclean.Lightly coat the wheel mounting spigot facewith a suitable anti-seize compound tominimise the possibility of adhesion betweenwheel and spigot face.Apply a drop of oil to the wheel studs.Refit the wheel taking care not to damage thestud threads.Fit the wheel nuts and turn by hand for atleast three full threads before using any formof wheel wrench.Tighten the nuts as much as possible using asuitable wrench.Remove and refitRemoving1. Remove the wheel.2. Drive the stud out of the driveshaft flange.RR2141E \ / NRefittingRR2142E10. Lower the vehicle and finally tighten the nutsto the correct torque (see section 06-Torquevalues) in the sequence shown.3. Position the stud in the flange.4. Install a suitable spacer over the stud.5. Using a Ml6 x 1.5P nut, a slave Range Roverwheel nut is suitable, pull the stud into theflange until the shoulder of the stud abuts theflange.6. Refit the wheel, tighten the wheel nuts to thecorrect torque (see section 06-Torque values).


.‘,.. . . ,: ;


;;;f; 1987CHASSIS AND BODY‘% BODY REPAIRS, GENERAL INFORMATION Welding.T...:The Range Rover body consists of a steel frame towhich alloy outer panels are attached. The cowlpanel, front fenders, side door outer panels, bodyside outer panels and roof are made from a speciallight magnesium-aluminium alloy.The manufacture of body panels from aluminiumhas two distinct advantages, the first of which is amuch better resistance to corrosion, the secondbeing a decrease in the gross vehicle weight.Aluminium panels can be effectively repaired usingthe ‘Argon Arc ’ process of welding, because theafore mentioned is a specialist operation it isnecessary that only a skilled operator or specialistbody shop undertake such repairs.Under certain conditions it may’ not be practical torepair an exterior damaged panel, if this is the case,then panels can be easily removed and replacedwith new ones (refer to the appropriate part of theBody section for panel removal and refit).Panel beating1. Aluminium alloy panels can be beaten outafter accidental damage in the same way assheet steel. However, under protractedhammering the material will harden, and thenit must be annealed to prevent the possibilityof cracking. This is quite easily done by theapplication of heat, followed by slowair-cooling, but as the melting point is low,heat must be applied slowly and carefully.CAUTION: Before applying heat to any panelensure that the panel is clean and free fromunderseal and that the area to be worked on iswell clear of any combustible materials. Ensurethat all necessary precautions are taken againstfire. IF HEAT IS TO BE APPLIED TO THE REARRIGHT HAND FENDER, THE FENDER MUST FIRSTBE REMOVED AS A FUEL EXPANSION TANK ISLOCATED BETWEEN THE FENDER AND INNERBODY SIDE.CAUTION: The battery ground lead MUST bedisconnected before commencing welding. IFWELDING IS TO BE CARRIED OUT ON THE REARRIGHT HAND FENDER, THE FENDER MUST BEREMOVED, AS A FUEL EXPANSION TANK ISLOCATED BETWEEN THE FENDER AND INNERBODY SIDE.1. Clean off all grease and paint, dry thoroughlyand then clean the edges to be welded, andan area at least half an inch on either side ofthe weld, with a stiff wire scratch brush orwire wool. Cleanliness is essential. Also cleanthe welding rod or strip with steel wool.2. It is strongly recommended that a few weldsare made on scrap metal before the actualrepair is undertaken if the operator is notalready experienced in welding aluminium andits alloys.3. Use only 5 per cent magnesium aluminiumwelding rod (5 Mg/A).Welding tears and patching1. If a tear extends to the edge of a panel, startthe weld from the end away from the edgeand also at this point drill a small hole toprevent the crack spreading, then worktowards the edge.2. When welding a long tear, or making a longwelded joint, tack the edges to be welded atintervals of from 2 in to 4 in (50 to 100mm)with spots. This is done by melting the metalat the starting end and fusing into it a smallamount of the filler rod, repeating the processat the suggested intervals. After this, weldcontinuously along the joint from right to left,increasing the speed of the weld as thematerial heats up.3. When patching, cut the patch to the correctshape for the hole to be filled, but of suchsizes as to leave a gap of l/32 in (0.80mm)between it and the panel, and then weld asdescribed above. Never apply an ‘overlay’patch.1 .‘,


76 ‘CHASSIS AND BODY1987 RANGEROVERc .Spot welding. 1. spot welding is mainly used in themanufacture of the Range-Rover inner steelbody frame and exterior magnesium-aluminiumalloy panels, and is a process which can becarried out satisfactorily by the use of theproper apparatus in a specialist body shop.Aluminium and its alloys are very goodconductors of heat and electricity, and thus itis most important to maintain the rightconditions for successful spot welding. Thecorrect current density must be maintained,and so must the ‘dwell’ of the electrodes.Special spot welding machines have beendeveloped, but they are expensive, andthough the actual work can be carried out bycomparatively unskilled labour, supervision andmachine maintenance must be in the hands ofproperly qualified persons.Riveting1. Where both sides of the metal are accessibleand it is possible to use an anvil or ‘dolly’solid aluminium rivets may be used, with asuitable punch or ‘pop’ to ensure cleanrounded head on the work. For riveting blindholes, ‘pop-rivets’ must be used. These areinserted and closed by special ‘Lazy-Tong’‘pop-rivet’ pliers.PAINTWORKGeneral InformationBefore undertaking any paintwork process on theexterior body of Range Rover, firstly ascertain whichis the best method of repair either by panel repairor replacement.The initial preparation of a panel is very importantto ensure that when finished it is of a standard thatmeets and matches existing bodywork. Panels mustbe thoroughly degreased with Berger Preclean802.0516 or a suitable equivalent, any unsoundpaint to be stripped using Berger Double strengthMeltic 301.8051. Always refer to the paintmanufacturers instructions.Paintwork processes should be performed by aspecialist bodyshop where paint spraying can beundertaken in a controlled environment wherebytemperatures are kept constant and the atmospheredust free.The flow chart on the following page gives a guideto preparing and painting a panel. Whereverpossible refer to the Berger Vehicle RefinishesProduct Data and Application Sheets for furtherinformation.j2


RANGE 1987ROVERCHASSIS AND BODYSUBSTRATEALUMINIUM PANELSIPANEL REPAIRIIREPLACEMENT PANEL‘REPARATIONVet for using P60 Grade paper or dryand using P240 grit discs.Wet flat using P60 Grade paper or drysand using P240 grit discs. Care mustbe taken to avord cutting through tobare aluminium.lODY FILLINGf filling is required, thoroughlylbrade bare alumrnium area to beilled and apply Standox PolyesterJopper 430-5029.If filling is required, fill smallindentations with Standox Polysterstopper 430-5029.iTCHlNGitch the bare aluminium and fillerThis process is not required if thewith auto-speed self etchoriginal electrocoat primer is inlrimer 414-1171, mixed 1:l with actrvator -1;;;zzondition.301-7995. Apply one coat andallow to dry for approximately 20ninutes.Zecoat within 1 hour.1‘RIMINGTo obtain maximum adhesion and excellent build, apply Standox2K 4:l full primer 405-0381. Coats of 30-40 microns can be wetflatted with P60 grade paper after 45 minutes at 20°C.COLOUR COATINGApply either Standox 2K Standocryl or Standox Metallic Basislack ,,to the colour required. Hardeners and thrnners will var)depending upon system employed, conditions available,temperature and size of vehicle etc. Refer to paint manufacturersTechnical Information Sheet for correct selection.REVISED: MARCH 90


CHASSIS AND BODYRANGE1987-90 ROVER: .I.> .I. .REVISED: APR. 87


;“o”;; 1987-90CHASSIS AND BODYCHASSIS FRAMEAlignment checkDiagram reference millimetres inches. . . .‘. :.:.:....AABBccDDEEFF12345678910111213A138141516171819202122232425262728293031Wheelbase-Reference dimensionCentre line of front axleCentre line of rear axleFrame datum lineSide member datum lineDatum line(with mounting washers)(without washers)Reference dimensionTo face of bossFrame datum to underside of cross-memberCheck figure2540.00 100.000254.00 + 0.63 10.000 + ,025263.525 + 1.91 10.375 + ,075- 0.63 - ,025261.11 2 2.54 10.180 + .I00266.70 + 2.54 10.500 2.100237.74 4 1.27 .9.360 + ,050327.81 f- 2.54 12.906 -f .I00979.93 + 1.27 38.580 2.0502244.72 + 2.54 88.375 + .I00356.74 + 2.54 14.045 +.100605.15 + 2.54 23.825 +.I001405.38 + 2.54 55.330 +-loo694.44 + 2.54 27.340 +.I00338.83 + 2.54 13.340 +.100222.25 2 5.08 8.750 2.200240.54 + 2.54 9.470 L.100794.91 31.296935.43 L 2.54 36.828 +.100150.79 5.937535.94 + 2.54 21.100 ~.I00590.55 + 0.64 23.250 2.025630.93 ~1.27 24.840 2.050344.17 + 1.27 13.550 +.050485.77 f 2.54 19.125 + .I00485.77 + 2.54 19.125 + .I00414.32 + 2.54 16.312 +.I00 .129.03 + 2.54 5.080 +.I002544.44 + 0.25 100.175 2.0101355.34 + 0.38 53.360 2.0151722.04 + 0.38 67.797 2.0152663.44 + 0.38 104.860 +.015144.09 2 0.38 5.673 +.QlS400.48 fL 2.54 15.767 +.lOO1333.88 + 0.38 52.515 2.015Continued5 " :


CHASSIS AND BODYRANGE1987-90 ROVERmillimetresinches.c,.32 Reference dimension33 Reference dimension34 Reference dimension925.49 36.437 . ..147.62 5 . 8 1 2635.00 25.000SECTION XX35 Frame datum line DD3637488.95 r. 2.54295.27 2 2.5419.250 + .lOO11.625 2.100SECTION W38 Frame datum line DD3940660.40 + 0.17MO.95 + 1.91- 0.6326.000 L.0073.187 + .075-.025SECTION ZZ41 Frame datum line DD42434480.95 + 1.91- 0.63660.4+0.179.525+2.543.187 + .075-.02526.000 _+_.0070.375 &.I00‘.’:,:_.


CHASSIS AND BODY (76 1BODYIntroduction:The information which follows is concerned solelywith the ‘Monocoque’ assembly of the inner bodyshell on Range Rover models.Body repairs often require the removal ofmechanical and electrical units and associatedwiring. Where necessary, reference should be madeto the relevant section of the Repair Manual forremoval and refitting instructions.The inner body shell is of ‘Monocoque’construction and to gain access to the repair area, itmay be necessary to remove exterior body panels,all exterior body panels are bolted to the innerbody shell to facilitate easier panel removal andreplacement or repair.Spot welding is satisfactory if the joints do not pullapart. If the weld pulls a hole or tears the metal theweld is satisfactory. It is defective if the weld jointpulls apart or if there are signs of burning, porosityor cracking evident.PREPARATIONThoroughly clean all areas to be welded, removeany sealants and corrosion protectives from aroundoriginal panels. Align and clamp all new panels inposition and check relationship to one another.Continued.’,.It is expected that a repairer will select the best andmost economic repair method possible, making useof the facilities available. The instructions given areintended to assist a skilled body repairer byexpanding approved procedures for panelreplacement with the objective of restoring the carto a safe running condition and effecting a repairwhich is visually acceptable.WELDINGThe following charts and illustrations show thelocations and types of weld for securing the bodyside assembly, tailgate frame assembly and the frontvalance and wheel arch assembly. Beforeundertaking any spot weld joints to the inner body,it is advisable to make a test joint using offcuts ofthe damaged components, and to use this testpiece to perform a weld integrity test.7


l-l 76 CHASSIS AND BODYRANGE1987-90 ROVERINNER BODY SHELL ASSEMBLYLOCATIONA. Front cross member tovalance and wheel archassemblyB. Hood locking platform tovalance and wheel archassemblyC. Valance and wheel archassembly to dash and tunnelassemblyFACTORY JOINT (minimum number ofspot welds quoted)6 spot welds, 20mm pitch10 spot welds, 25mm pitch16 spot welds, 25mm pitch0. Body side complete to dash IO spot welds, 65mm pitchand tunnel assembly


R”o”v‘;l: 7 987-90CHASSIS ANn Rnnv hiI./.::. . :.:::1.. ., ........*.,:.: .;LOCATIONLOCATION EE. 1. Body side complete toheelboard panel assembly.2. Body side complete todash and tunnel assemblycomplete.3. Body side complete to dashand tunnel assemblyLOCATION FFACTORY JOINT (minimum number ofspot welds quoted)14 spot welds, 35mm pitch10 spot welds, 25mm pitch3 spot welds, 30mm pitch-. I. Body side complete todash and tunnelassembly complete2. Body side complete todash and tunnelassembly complete3. Body side complete todash and tunnelassembly complete7 spot welds, 30mm pitch18 spot welds, 40mm pitch30 spot welds, 34mm pitchContinued9


.I 76 CHASSIS AND BODYRANGE1987-90 ROVERLOCATIONLOCATION CG. 1. Reinforcement plate todash and tunnel assemblyand body side assemblycompleteH. 1. Body side complete to roofheader panel assembly(internal joint)2. Body side complete to roofheader panel assembly(internal joint)LOCATION HFACTORY JOINT (minimum weldrequirement quoted)CO, weld, 2 places 75mm longeach weld3 spot welds, 15mm pitch3 spot welds, 15mm pitch;:


.‘.LOCATION JLOCATION KLOCATIONI. 1. Body side complete to reartailgate frame assemblyK. 1. Body side complete to roofheader panel assembly(external joint)2. Body side complete to roofheader panel assembly(external joint)FACTORY JOINT (minimum weldrequirement quoted)CO? weld, one run 40mm longCO? weld, one run 20mm longCO* weld, one run 100mm longContinued1 1


l-l 76 CHASSIS AND BODY 1987-90 K:,:;ILOCATIONLOCATION LL. 1. Body side complete to reartailgate side memberM. 1. Body side complete to reartailgate bottom crossmemberLOCATION MFACTORY JOINT (minimum weldrequirement quoted)32 spot welds, 30mm pitchCO2 weld, 2 runs 40mm long:..‘.. ..’‘. ..,.,. :.:.,:.,..‘_ ....


:KANutROVER 1987-90 CHASSIS AND BODY (76 1RR1562M‘.’:I.LOCATION NLOCATIONN. 1. Valance and wheel archassembly to dash andtunnel assembly2. Valance and wheel archassembly to dash andtunnel assembly.FACTORY JOINT (minimum number ofspot welds quoted)4 spot welds, 45mm pitch15 spot welds, 25mm pitchi’ .;;,,p:. .._13 Y’),‘.


76 CHASSIS AND BODYRANGE1987-90 ROVERHEADLINING AND ROOF PANELRoof panel. . . . .Remove and refit9. Remove the screws (with washers) fromaround the inner edge of the roof panel.Removing10. With assistance lift the roof panel from thebody, remove any previous sealingHeadliningcompounds from around the edge of the roofpanel and body.1. Remove the two roof lamp assemblies.2. Remove the rear view mirror and mounting Refittingbracket.3. Remove the two sun visors and centre 11. Apply a waterproof sealant to roof and bodyretaining bracket.mating faces.4. Remove the front and rear passenger grab 12. Reverse the removal instructions 1 to 9.rails.5. Pry out the two plastic retaining clips securingthe centre of the headlining to the roof panel.6. With assistance support the front of theheadlining while releasing the two rear fixingsabove the rear quarter light glass.7. While the headlining is still being supportedpry out the two plastic retaining clips securingthe rear end of the headlining, locatedadjacent to the upper tailgate hinges.CAUTION: To avoid damage and to assist in theremoval of the headlining from the vehicle,slightly flex the headlining as shown in theillustration below.8. Lower the headlining and disconnect theelectrical leads from the rear radio speakers,remove the headlining from the vehicle.HOOD-COWL PANEL-FRONT FENDERRemove and refitRemovingCAUTION: The assisted hood lift mechanismalone will not retain the hood in its fully openposition. Always secure the hood stay to supportan open hood.Open the hood and disconnect the batterynegative terminal.Disconnect the under-hood lamp electricalleads.Disconnect the windscreen washer tube at the‘T’ joint.Release the four bolts securing the hood tothe hinges, note the ground strap locatedunder the upper left hand hood fixing, withassistance lift the hood clear of the vehicle.Cowl panel.‘,Remove the wiper arms and two nuts securingthe wheel boxes to the cowl panel andremove the two exterior sealing rubbers.Remove the nine cross-head screws securingthe front of the cowl panel.Remove the four bolts (with spring and plainwashers) retaining the cowl panel to the topof the fenders, retrieve the nylon spacingwashers from between cowl panel and fender.:.’ 14,.., .:.:


::’R”o”v’;; 1987CHASSIS AND BODY‘...,.RR2129E,:,’8. Remove the four cross-head screws retainingthe panel to the ‘A’ post mounting bracketslocated above the front door hinges.9. With assistance place a tube over each of thehinges and lower to enable the cowl panel tobe fed over the hinges, carefully return thehinges to their upright position.16. Remove the two bolts (with plain washers)securing the sill finishing strip to the bottomof the fender.17. Remove the two cross-head screws securingthe fender to the mounting bracket attachedto the ‘A’ post located in between the frontdoor hinges.Front fenderRefitting._,’10. Remove the two cross-head screws from thetop of the front side light assembly, maneuverthe assembly out of the two bottom locationholes.11. Remove the bulb holder waterproof cover,depress the two retaining clips and withdrawthe bulb holder from the rear of the lamp unit.Remove the lamp unit.12. Remove the two screws (with plain washers)from the bottom of the side light recess.13. Remove the three fixings securing the bumperwrap around end cap and remove themoulding from the bumper.14. Remove the bolt which secures the end of thespoiler to the front of the wheel arch, locatedforward of the road wheel at the bottom ofthe fender.15. Remove the five nuts and bolts (with plain andspring washers) securing the top edge of thefender to the wheel arch and valanceassembly.Front fender18. Apply a suitable underseal to the inner face ofthe fender and a waterproof sealant to thefender to wheel arch/valance mating faces.19. Ensure that before final tightening of thefender securing bolts the fender aligns withthe edge of the front door.20. Reverse remaining fender removal instructions.Continued.REVISED: JULY 88 15


.‘.:.’.>:r:.. . .,.’,:/xi:,.Cowl panel21.22.23.24.Hood25.26.CHASSIS AND BODYLower the hinges to enable the cowl panel tobe fitted.Fit the securing bolts ensuring that any nylonspacers previously removed are refitted in theiroriginal position.Using a soft blunt implement ease thewindscreen rubber up onto the top of thecowl panel.Reverse the remaining cowl panel removalinstruction.Fit the hood ensuring that before finaltightening of the securing bolts, the engineground strap is refitted to the forward bolt ofthe left hand hinge, and that the hood alignswith the cowl panel, fender and front grille,adjust the hood at the hinges as necessary.Reverse the remaining removal instructions.ASSISTED HOOD LIFT1987 lWNGtROVERNOTE: An engine ground strap is attached to theforward bolt of the left hand hinge and must berefitted when the hood is re-bolted to thehinges.6. With assistance lift the hood clear of thehinges and store safely to one side, coverhood to protect paintwork.:Remove and refit 7.Removing 8.CAUTION: The assisted lift mechanism of thehood eases the hood opening and lift procedure.When the hood is fully open, secure the hoodstay in position. The assisted lift mechanismalone WILL NOT retain the hood in its uprightposition.Remove the two wiper box wheel nuts andrubber spacers.Remove the four fixings securing the cowlpanel to the front fenders, the front twofixings are accessible from the front of thecowl panel, access to the rear two fixings isgained by opening the front doors. Note thenylon spacing washers at each bolt.Carefully pry the wiper arms off the spindlebosses, noting their position for re-assembly.Raise the hood and disconnect the batterynegative terminal.Disconnect the electrical lead to the hoodillumination lamp.Disconnect the screen washer fluid feed pipeat the IT’ joint, remove the feed pipe from thehood retaining clip.‘... :NOTE: The removal of the hood will require theassistance of a second person.5. Release the four bolts (with plain washers)securing the hood to the hinges.9. Remove the nine cross-head screws from thefront of the cowl panel water channel.16 REVISED: JULY 88: .i.;:I..


PO;;; 1987CHASSIS AND BODY10. Place extension tubes over each hood hinge,with assistance lower the hinges,maneuver thecowl panel off the wiper arm shaft bosses andalong the tubes until the panel is clear of thevehicle. Place the panel to one side and coverto protect paintwork.WARNING: Gradually let the torsion bar springtension return the hinges to their uprightposition to prevent the possibility of personalinjury or damage to the vehicle.11. Place an extension tube over the hinge, lowerthe hinge until the stop bracket can beremoved, withdraw the bracket and graduallyallow the hinge to return to its uprightposition.15. Remove the two bolts (with plain washers)securing the hinge to its mounting bracket.16. Withdraw the hinge.Refitting17. Fit the hinge and securely tighten the tworetaining bolts (with plain washers).18. Fit the torsion bar ensuring that it is securelylocated in the retaining clip and bracket.I 9. Reverse the remaining removal instructions.NOTE: Fit the ground strap under the forwardbolt of the left hand hinge.20. Using a soft blunt implement ease the bottomlip of the windscreen seal up and over ontothe face of the cowl panel.‘.12.: 13.14.Release the torsion bar from the retaining clip.Maneuver the torsion bar until it can bereleased from the hinge.Release the torsion bar from the retainingbracket.,’17‘.


CHASSIS AND BODYRANGE“*’ ROVER:REAR CORNER PANEL AND FENDERRemove and refitCAUTION: IF A REPAIR IS BEING UNDERTAKENON OR AROUND THE AREA OF THE REAR RIGHTHAND FENDER AND HEAT IS TO BE APPLIED,THE FENDER MUST BE REMOVED, AS A FUELEXPANSION TANK IS LOCATED BETWEEN THEFENDER AND INNER BODY SIDE.RemovingNOTE: Ensure the central locking system isde-activated to enable the fuel filler flap to beopened, disconnect the battery negativeterminal.I. Open the fuel filler flap and remove the threefiller tube securing screws.(Right hand rearfender only)9 From inside the slowage area remove the fivecross-head screws securing the top of thefender to the bodyside panel. If necessary foldthe rear seat forward and remove the seatlocking mechanism housing to gain access tothe screw adjacent to the ID’ post.. .. .RR2130E2. Remove the rear stowage area parcel shelf andspare wheel.3. Remove the two nuts (with washers) securingthe bumper wrap around end cap to thebottom of the corner panel.4. Remove the single bolt securing the end capto the bumper, accessible from behind thebumper.5. Remove the fixings and release the rear taillight cluster from the rear corner panel anddisconnect the electrical plug.6. Drill out all the pop-rivets securing the cornerpanel to the tailgate frame.7. Remove the two nuts and bolts securing thefront of the fender to the ‘D’ post locatedbeneath the wheel arch.8. Release the single nut and bolt retaining themud-flap bracket to the bottom of the fender.10. Remove the rear fender and comer panelcomplete.11. Remove the seven bolts (with plain and springwashers) securing the fender to the cornerpanel and separate the two panels.Refitting12. Assemble the corner panel to the rear fender,fit the bolts and ensure both panels alignbefore final tightening.


;“d”;; 1987CHASSIS AND BODY rid13. Coat the underside of panels with a suitableunderseal.14. Fit the assembly to the vehicle ensuring thatthe door edge to fender edge and cornerpanel to lower tailgate are in alignment beforethe fina; tightening of screws and the fitting ofpop-rivets.15. Reverse the remaining removal instructions.REAR QUARTER PANEL-INTERIORRemove and refitRemovingNOTE: If removing the drivers side interioror exterior quarter panel it will benecessary to remove the spare wheel fromthe rear stowage area.. . . >FUEL FILLER FLAPRemove and refitAdjustRemovingNOTE: The fuel filler flap is locked when thevehicle central locking system has beenactivated, ensure the system has beende-activated before attempting to open the flap.1.2.3.4.5.Detach the plastic cover from the upper seatbelt guide bracket and remove the single bolt.Remove the clip-on plastic cover from the seatbelt inertia reel. Remove the retaining bolt andplace the inertia reel to one side.Release the two small cross-head screwssecuring the trim panel to the body side.Ease the front of the trim panel from behindthe quarter light glass rubber moulding.Withdraw the panel from the vehicle.I. Open the fuel filler flap.2. Release the two screws (with plain washers).3. Withdraw the flap.RefittingRR2073ERefitting4. Fit the flap, but do not fully tighten the screwsat this stage.5. Close the flap and check that the outer profileof the flap aligns with the rear fender, adjustby easing the flap in or out of the opening.6. Open the flap and securely tighten the screws.Ease the top front edge of the trim panel(approximately the first 25mm, 1 inch) as closeto the headlining as is possible under the lipof the rubber moulding.Push the panel up behind the headlining untilthe cross head screw holes line up with theirrespective holes in the bodyside.Using a soft blunt implement ease the rubbermoulding lip over the remainder of the frontof the trim panel.Continued,_..’‘.;19


CHASSIS AND BODY1987 ;;rv;r;9. Ensuring that the electrical harness is locatedin the channel at the rear of the trim panel fitthe two crosshead screws.10. Ensuring that the seat belt is not twisted fit theguide bracket and inertia reel, tighten the twobolts to the specified torque (see section06.Torque values).71. Refit the plastic cover to the guide bracket.REAR QUARTER PANEL-EXTERIORRemove and refitRemovingNOTE: If removing the drivers side interioror exterior quarter panel it will benecessary to remove the spare wheel fromthe rear stowage area.:.::: .’1. Remove the rear seat belt inertia reel andguide bracket.2. Remove the two crosshead screws and detachthe interior quarter panel.3. Remove the three nuts (with plain washers)securing the exterior quarter panel to thebodyside. The nuts are accessible through thelarge holes located adjacent to the rear quarterlight.4. Remove the four screws securing the quarterpanel to the inside edge of the tailgateopening.5. Withdraw the panel.:Refitting6. Reverse the removal instructions.7. Ensure that the seat belts, inertia reel andguide bracket bolts are tightened to thespecified torque (see section 06-Torquevalues).: ,‘.


FOE; 1987CHASSIS AND BODY‘. ‘.‘.’ ,:.I ; ’i.,, , b..‘:v’-,“...+UPPER TAILGATERemove and refitRemovingUPPER TAILGATE-LOCKRemove and refitRemovingDisconnect the battery negative lead.Remove the tailgate wiper arm.Open the tailgate and remove the four screwssecuring the two rear screen electrical leadshrouds located at either end of the tailgate.Maneuver the shroud away from the screenand out of the leadlining to reveal theelectrical connections, disconnect the leads.1.2.Remove the two cross-head screws securingthe upper tailgate release handle.Ease the sealing rubber away to reveal thesingle screw securing the centre of the releasehandle, remove the screw and detach thehandle from the lock mechanism completewith key barrel.WARNING: If a tailgate stay is weak, DO NOTattempt to repair the unit. Fit a replacement...‘; .(5. Pry the two stays off the tailgate.6. Remove the four hinge to tailgate screws.RR1622M - i I I IINOTE: At this stage the barrel can beremoved from the handle by releasing thetwo small cross-head screws at thejoint-face. Remove the retaining plate andrelease the spring and key barrel from itsbore.7. Lift the upper tailgate clear.Refitting8. Reverse the removal instructions.3. Release the eight screws and remove theoperating rod covers located either side of thecentre lock mechanism.4. Remove the four screws and two nuts securingthe lock catches to the sides of the tailgate.RR1623M //Continued21


CHASSIS AND BODY1987 IWNbtROVER,,:’,,., :5. Release the two small locknuts on theoperating rods and rotate the hexagonalconnecting rod until the side catches can beremoved.6. Release the two screws securing the centrelock mechanism and remove the unitcomplete with operating rods.Refitting7. Reverse the removal procedure.8. Adjustment of the side catches may berequired after assembly, this is achieved byreleasing the locknuts on the operating rods,and rotating the hexagonal link clockwise orcounter-clockwise to shorten or extend thelength of the operating rods.LOWER TAILGATERemove and refitRemoving1. Disconnect the battery negative terminal.2. Carefully pull the electrical leads out of thebottom of the lower tailgate to reveal the snapconnectors. Access to the leads is gainedbetween the top of the bumper and bottomof the tailgate.2:,‘. .,RR2 143ERemove the four cross-head screws securingthe sealing rubber around the tailgate hingebolts.Remove the fixings, tailgate to hinges.Disconnect the check straps.With assistance withdraw the tailgate.RR2144Edefitting7. Reverse 1 to 5.8. Ensure that the rubber grommet is relocated inthe bottom of the tailgate.. . . ..,j.22


.;.:... . .ro;;l; 1987CHASSIS AND BODY 176 1LOWER TAILGATE RELEASE MECHANISMRefittingRemove and refitRemoving12. Reverse the removal procedure, lightly greasethe handle release actuator lever and internaltailgate operating lever..a‘.‘.‘,,,1. Open and raise the upper tailgate.2. Release and lower, the lower tailgate.3. Lift the trim panel off the tailgate inner panel.4. Remove the screws securing the lock coverplate.5. Remove the cover plate complete with handlerelease mechanism.6. Remove the two screws and detach the handlerelease actuator lever.7. Remove the two nyloc nuts and detach thehandle release retaining bracket.8. Withdraw the handle release mechanism fromthe cover plate.LOWER TAILGATE STRIKER ADJUSTMENTAdjust1. Open and raise upper tailgate.2. Open and lower, lower tailgate.3. Release the striker and move in theappropriate direction, either add or subtractspacing washers between the striker andtailgate opening.4. Adjustment is correct when outer profile oftailgate panel aligns with both rear bodycorner panels.\ \\ I,;.:,, .1.x.:..,..RR2001E9.10.11.Release the spring clips securing the operatingrods to the internal tailgate releasemechanism.Remove the screws securing the exterior locksat either side of the tailgate.Withdraw the exterior locks with operatingrods.23


l-lRANGt76 CHASSIS AND BODY “*’ ROVERRADIATOR GRILLERemove and refitRemoving1. Raise the hood and secure the hood support.2. Depress the four upper retaining lugs and easethe grille forward.3. Lift the grille upwards and withdraw it fromthe vehicle.FRONT DOORRemove and refitRemoving1.2.3.4.Disconnect the battery negative lead.Open the appropriate door to be removed.Remove the two screws and detach the sidetrim panel from the front footwell.Carefully pull the door wiring harness fromabove the dash until the electrical plugs areexposed.Disconnect the electrical plugs and feed themthrough the opening in the ‘A’ post.Drive out the roll pin from the door checkstrap.With assistance support the door and removethe screws, securing door to hinges.Lift the door clear.Refitting4. Fit the radiator grille ensuring that the bottomlugs of the grille locate in their respective slotsbelow the headlamp units.5. Ease the grille rearwards and locate the upperretaining lugs.Refitting9. Refit the door and feed the electrical cablesthrough the ‘A’ post.10. Fully open the door and reconnect theelectrical leads, take up the slack in the leadsand clip them securely to the footwell sidepanel, refit the convolute grommet to the ‘A’post frame.11. Check the location of the door and theoperation of the door lock. If necessary, adjustthe door and striker plate.:.,’:.:2 4. . :‘.’::,_ .:i ;::,,... .


o;;; 1987CHASSIS AND BODY bii.‘,.,:a ‘::, ‘:;,’,. : :12. Adjust the door by the addition of shimsbetween the hinge and door or hinge and ‘A’post to take the door forward or rearward inthe opening.13. By loosening the six screws securing thehinges to the door, the door can be adjustedup and down or in and out of the opening.14. The door lock striker can be adjusted byloosening the striker and moving it in theappropriate direction or adding andsubtracting spacing washers between thestriker and ‘B’ post.FRONT DOOR GLASS AND REGULATORRemove and refitRemoving1. Ensure the window is in its fully closedposition and secure it with adhesive tape toprevent the window dropping down.2. Disconnect the battery negative terminal.3. Detach the armrest/door-pull finisher to revealthe two securing screws.4. Remove the two securing screws (with plainwashers) to enable the armrest/door-pull to bedetached from the inner door panel.5. Remove the interior door handle finisherbutton to reveal the screw retaining thehandle surround.6. Remove the screw and detach the handlesurround from the inner door panel.7. Detach the inner door trim pad by inserting ascrewdriver between the trim pad and innerdoor panel, gently pry out the nine plasticsecuring clips from their respective holes inthe inner door panel.8. Disconnect the two speaker connectionsinside the door and remove the door trim padcomplete with speaker.9. Remove the plastic vapor barrier.10. Remove the window lift motor (refer toElectrical Section).Ii. Remove the four window regulator retainingbolts with shakeproof washers from the innerdoor panel...:,1RklEh38M ’I IContinued. ‘......:..‘.25‘,..,


CHASSIS AND BODY,987 KANLtROVERRemove the two screws with shakeproofwashers retaining the lower window liftchannel and slide the channel off the stud.Disengage the lifting arm stud from the upperlifting channel, maneuver the windowregulator and remove if from the lower centreopening in the inner door panel.20.21.23.24.25Remove the bolt (spring and plain washer)from the recessed hole in the front of theinner door panel under the exterior drivingmirror mounting plate.Remove the single screw (spring and plainwasher) from inside the door securing thebottom front glass channel.Remove the single screw (spring and plainwasher) from inside the door securing thebottom rear glass channel.Lift the door glass frame complete with glassout of the door panel and remove to asuitable bench.Remove the adhesive tape securing the glassto the frame.Slide the glass out of the door frame channel... -Refitting14.15.16.17.Remove the sill locking knob.Remove the inner door capping off its keyholelocation.Remove the exterior driving mirror (refer toexterior driving mirrors removal and refit inElectrical Section).Remove the waist rail seal from the top of thedoor panel.26. Reverse the removal instructions, items 1 to25.NOTE: When refitting the door glass frame,ensure it is repositioned to suit the dooropening before fully tightening the doorframe securing bolts.FRONT DOOR LOCK, OUTSIDE AND INSIDEDOOR RELEASE HANDLESRemove and refitRemoving. .i‘i.1.2.3.4.5.Remove the window lift motor (refer toElectrical Section).Remove door glass and regulator (refer todoor glass and regulator remove and refit).Remove door actuator units (refer to ElectricalSection).Disconnect the control rod from the privatekey operated lock by releasing the metal clipat the bottom of the rod.Disconnect the control rod from the outsidedoor release handle by pulling it out of theplastic ferrule.18. Remove the two bolts fshakeproof and plainwashers) from the hinge face of the doorwhich secure the front door frame.19. Remove the single bolt (spring and plainwasher) from the edge of the door whichsecures thd door rear frame.2 6


o;$ 1987CHASSIS AND BODY.!6. Disconnect the control rod connectorbetween the inside door release handle andthe door lock by releasing the metal clip andpulling one of the control rods out of theplastic connecting block. This is accessiblethrough the small centre cut-out in the doorpanel. (The control rod also passes through aguide bracket on the inside of the inner doorpanel).7. From inside the door panel push out the smallpin which secures the quadrant to the innerdoor panel. Push the quadrant out of thepanel.8. Release the door lock by removing the twocounter-sunk screws from the door edge andthe single screw (with shakeproof washer) onthe inner door panel.9. Withdraw the lock through the lower rearcut-out on the inner door panel.NOTE: If necessary the following items canalso be removed.10. Remove the two nuts (with shakeproofwashers) and retaining bracket securing theoutside door release handle to the outerdoor panel, accessible through the upper rearcut-out on the inner door panel.11. Carefully detach the door release handle fromthe outer door panel.12. Remove the two screws securing the insidedoor release handle to the inner panel.13. Withdraw the handle from its location withhalf the connecting rod still attached.14. Unclip the spring tensioned end of theconnecting rod from the door release handle.Refitting15. Reverse the removal procedure items 1 to 13.NOTE: When refitting the door glass frame,ensure that it is positioned to suit the dooropening before fully tightening the doorframe securing bolts.. ..b27


CHASSIS AND BODYRANGElg8’ ROVERADJUSTMENT-FRONT DOOR LOCK AND HANDLEASSEMBLYInside door release handle to lock1. Refit the inside door release handle surroundbefore any adjustment is made, allowing thehandle to be set from the correct operatingposition.2. Rotate the spring tensioned nyloc nut at theopposite end of the interior handleconnecting rod, clockwise 01counter-clockwise to shorten or extend theoperating length.Outside door release handle to lock3. Disconnect the connecting rod at the rear ofthe outer door release handle by releasing itfrom the plastic ferrule rotate the rodclockwise or counter-clockwise to shorten orextend the operating length, refit the rod tothe ferrule.REAR PASSENGER DOORRemove and refitRemoving1.2.3.4.5.6.Disconnect the battery negative lead.Pull the convolute grommet out of the face ofthe ‘B’ post.Withdraw the electrical leads from the ‘B’ postuntil the electrical plugs are exposed anddisconnect the plugs.Remove the two bolts (with spring and plainwashers) securing the door check strap.Open the door slightly, support the door andremove the six bolts (with spring washers)securing the hinges to the ‘B’ post.Lift the door clear.,NOTE: Door release should be effectivebefore the total handle movement isexhausted to provide a small overthrowmovement.RefittingReverse the removal procedure.Adjustment to the rear doors is made byreleasing the six hinge securing bolts (hinge to‘B’ post) and moving the door eitherrear-wards. forward, up or down in the dooropening.Adjustment to the door striker is identical tofront door adjustment.


;^d;‘;r; 1987CHASSIS AND BODYIREAR DOOR GLASS AND REGULATORRemove and refitRemoving2.3.4.5.6.7.8.9.10.11.12.13.Ensure the window is in its fully closedposition and secure it with adhesive tape overthe top of the door to prevent the windowdropping down.Disconnect the battery negative terminal.Remove the armrest/door-pull finisher to revealthe two securing screws.Remove the two securing screws (with plainwashers) and detach the armrest/door-pullfrom the inner door panel.Disconnect the window lift switch multi-plugat the rear of the armrest/door-pull.Remove the interior handle finisher button 10reveal the screw retaining the handle surround.Remove the screw and detach the handlesurround from the door trim pad.Remove the door trim pad by inserting ascrewdriver behveen the trim pad and theinner door panel, gently pry out the six plasticclips from their respective holes around theedges of the trim.Remove the sill locking button.Remove the inner door capping from itskeyhole location.Remove the plastic vapor barrier.Remove the window lift motor (refer toElectrical Section).Remove the four window regulator securingscrews (with shakeproof washer).14. Carefully disengage the lifting arm stud fromthe glass lifting channel and remove thewindow regulator from the lower opening inthe inner door panel.15.16.17.18.19.20.Remove the waist rail seal from the top of thedoor panel.Remove the single bolt (with spring and plainwashers) from inside the door which securesthe bottom of the short rear glass run channel.Remove the two bolts (with spring and plainwashers) from the hinge face of the door.Remove the two bolts (with spring and plainwashers) from the edge of the door whichsecure the rear door frame.Lift out the door frame with the glass inposition and remove to a suitable workbench.Remove the tape and slide the glass out of thedoor frame channel.NOTE: When refitting the door glass framesecuring bolts, ensure that the door frameis adjusted to suit the door opening beforefully securing the frame to the door.ConticuedREVISED: DEC. 8729‘. I..


l-l 76 CHASSIS AND BODY1987 ro;;;REAR DOOR LOCK, OUTSIDE AND INSIDE DOORRELEASE HANDLESRemove and refitRemoving1. Ensure the window is in its fully closedposition.2. Remove all the interior door trim (refer todoor glass and regulator remove and refit,items 2 to 11).3. Disconnect the control rod from the insidedoor release handle by pulling the rod out ofits location at the door lock.4. Disconnect the sill locking control rod fromthe door lock by releasing the metal clip.5. Disconnect the control rod from the outsidedoor release handle by pulling it out of theplastic ferrule.6. Release the door lock by removing the twocounter-sunk screws from the door edge andthe single screw (with shakeproof washer) onthe inside of the door. Retrieve any spacingwashers which may be fitted between theinner door panel and the lock.7. Withdraw the lock through the upper rearopening in the inner door panel.NOTE: If necessary the following items canalso be removed.8. Remove the two nuts (with shakeproofwashers) and retaining bracket securing theoutside door release handle to the outerdoor panel, accessible through the upper rearcut-out on the inner door panel.9. Carefully detach the outside door releasehandle from the outer door panel.10. Remove the two screws (with plain washers)securing the inside door release handle tothe inner door panel.11. Withdraw the handle from its location with theconnecting rod still attaclred.12. Unclip the spring tensioned end of theconnecting rod from the door release handle.ContinuedREVISED: DEC. 87


po;g 1987CHASSIS AND BODY 1761Sill locking quadrants13.14.15.Use a-small screwdriver, or 3.175mm diameter(l/8 in) rod, press the plastic locking pinsthrough the respective square inserts in theinner door panel, until they can be retrievedfrom inside the door.Release the quadrants from the inner doorpanel and unhook the respective connectingrods.Withdraw the quadrant from inside the door.NOTE: When refitting the quadrants theplastic locking pins are entered into thesquare insert from outside and pressed inflush.ADJUSTMENT-REAR DOOR LOCK AND HANDLEASSEMBLYOutside door release handle to lock.l.Disconnect the short offset connecting rodat the rear of the outer door release handle,rotate the rod clockwise or counter-clockwiseto shorten or extend the operating length.NOTE: Door release should be effectivebefore the total handle movement isexhausted to provide a small over-throwmovement.Refitting.,: 16. Reverse the removal procedure 1 to 15.,//m216aE !,! :


76 CHASSIS AND BODY/RANGElg8’ ROVERWINDSCREEN CLASSRemove and refitRemovingCAUTION: Place a protective covering over thecowl panel and dashboard to prevent damage tothe bodywork and also to prevent broken glassentering the heater system.11. Work the glass into the bottom of thewindscreen rubber using a soft blunt ‘..implement shaped with a wedge type point,working up and around the seal and at thesame time pushing the screen onto therubber, ease the lip of the seal over thewindscreen glass as illustrated.1.2.3.4.5.Remove the windscreen wiper arms.Remove the expander strip from the channelin the rubber moulding around the glass.Remove the rubber moulding from thewindscreen opening.Remove any previous sealing compound fromaround the opening.Thoroughly clean the windscreen opening andremove any broken glass.RefittingCAUTION: To ensure a good bond is achievedbetween windscreen and rubber DO NOT usepetroleum based solvents or liquid soap to cleanor aid assembly of the windscreen to rubber.6.7.8.9.IO.Apply Sikaflex 207 cleaner primer to thewindscreen and rubber to remove any oilbased film that may be present.Apply Sikaflex 221 or 255 adhesive sealant tothe exterior channel of the NEW rubbermoulding, ensure the sealant is applied to thebottom of the channel.Fit the rubber moulding to the windscreenopening.Ensure that the edge of the ‘A’ post interiortrim panels are fitted under the lip of therubber moulding.Fit the windscreen into either bottom cornerof the rubber moulding channel.12. Apply Sikaflex 221 or 255 adhesive sealantbetween the outer lip of the rubber mouldingand exterior surface of the windscreen, ensurethe sealant is applied to the bottom of thechannel.CAUTION: To aid assembly of expander strip tothe windscreen rubber apply a small amount ofsoap solution to the channel on the face of therubber. Ensure that the soap solution is appliedto the.channel only.-. . . .1‘*,13. To aid insertion apply mineral spirit to therubber expander strip channel.32 :


PO;;; 1987CHASSIS AND BODYFit the expander rubber to the channel, do notoverstretch the rubber.If any of the rubber strip protrudes beyondthe channel after fitting, trim off at 45” with asharp knife.REAR QUARTER LIGHT GLASSRemove and refitRemoving1. Remove the rubber moulding from around theglass opening.2. Thoroughly clean the opening to be glazed.RefittingNOTE: If a new glass and moulding is beingfitted to the driver’s side quarter light it willbe necessary to remove the spare wheel.RR2151E16.17.18.19.20.Surplus sealant between screen and rubbermoulding will be forced out after the expanderstrip is fitted.Remove the surplus sealant, and wipe awaythe remaining sealant using Sikadur cleaner.With a blunt instrument lift the bottom of therubber moulding up and over onto the top ofthe cowl panel, likewise repeat the operationto bring the bottom of the rubber mouldingup and over onto the dashboard.Refit the wiper arms, check the wiper sweep iscorrect.Reverse the remaining removal instructions.3. Fit the new moulding to the glass.4. Fit a draw cord around the exterior surface ofthe rubber moulding ensuring that it sitssecurely in the bottom of the mouldingretaining channel.5. Coat the glass opening in the body side withliquid soap to aid assembly.6. Fit the glass and moulding to the glassopening ensuring that the draw cord is fedinto the interior stowage area.NOTE: It may be necessary to remove theseat belt inertia reel and cover.7. With assistance from a second operatorpushing the glass and moulding into theopening pull the draw cord from the mouldingenabling the seal to ride up over the bodysideretaining lip.8. Ensure the interior trim lies under the rubbermoulding.TAILGATE CLASSRemove and refitRemoving1. Remove the upper tailgate.2. Remove the lock.3. Remove the lift handle and trim.4. The upper tailgate glass and frame are servicedas one unit.Refitting5. Reverse instructions 1 to 3.


76 CHASSIS AND BODY1987 RANGEROVERFRONT SEATRemove and refitRemoving1.2.3.4.5.Remove the single screw securing the seatbase side trim panel and withdraw the panel.Remove the three screws securing the seatbase front trim panel to the front footwell,remove the single screw securing the top ofthe front trim panel to the seat base locatedunder the seat base cushion, and withdraw thepanel.Remove the three fixings securing the seatcushion side trim panel and withdraw the6. Move the seat until it is in its most forwardposition.7. Remove the four fixings securing the rear ofthe seat located inside each seat slide channel.8. Disconnect the battery negative terminal.9. Disconnect the electrical multi-plugs to theseat motors and seat control switch.10. Withdraw the seat from the vehicle.11. If necessaqr the seat motors and operatingswitch can be removed. (Refer to Section 86Electrical).Refitting12. Reverse the removal instructions.13. Arrange the electrical leads beneath the seatpanel. Remove the bolt securing the seat belt to ensure that they do not become trapped b)to the side of the seat.the seat slide mechanism.Move the seat until it is in its most rearwardposition.Remove the two fixings securing the frontthe seat located in each seat slide channel.ofRR2152E. .,.’,,‘. ‘


PO;:; 1987CHASSIS AND BODYASYMMETRIC SPLIT REAR SEATRemove and refitRemoving1. Lift the finger button to release the seat backrest securing catch and fold the seat forward.2. While folding the seat forward feed the rearseat lower part of the seat belt through theopening between the seat back and cushion.Refitting5. Reverse the removal procedure ensuring thatall fixings are securely tightened.6. Adjust the seat mechanism plate if necessary.ASYMMETRIC SPLIT REAR SEATLOCKING MECHANISMRemove and refitRemoving..-I. Lift the finger button and fold the seat backrest forward.2. Remove the spring clip securing the fingerbutton operating rod to the lock mechanismlever, accessible through the lock mountingbracket, withdraw the finger button.‘.3. Fold the seat fully forward and remove thefour rear pivot bracket bolts.4. Fold the seat back and lift the rear footwellcarpet from just below the front of the seat togain access to the four front fixings securingthe pivot brackets, remove the bolts, withdrawthe seat assembly from the vehicle.RR2058E3. Remove the trim stud and remove trimcovering.4. Remove the three screws from the face of thelock catch plate.5. Maneuver the catch plate off the lockmechanism.6. Retrieve the lock. mechanism from themounting bracket opening.ContinuedRR2057E 4\.~:;.:,:tiREVISED: JULY 88 35


IRANGE76 CHASSIS AND BODY “*’ ROVER‘.ASYMMETRIC SPLIT REAR SEATLOCKING MECHANISMAdjust1. Release the finger button and fold the seatback rest forward.2. Loosen the three screws securing the catchplate to the lock mechanism.3. Maneuver the lock assembly eitherhorizontally, vertically or diagonally until thecatch plate aligns with the striker at the side ofthe seat.4. Securely tighten the retaining screws.Refitting7. Lightly grease the internal lock mechanism.8. Reverse the removal instructions.9. Adjust the lock catch plate to align with theseat striker.iRR2060E3 6REVISED: JULY 88


CHASSIS AND BODYA-SEAT BELTSDescription,.‘I ,:..s*.:The seat belt assemblies are factory fitted in thecorrect location. If removal is necessary theprocedures in this section must be followed. Aflseat belt fixings MUST be tightened to the correcttorque (see section 06-Torque values).Seat belt assemblies MUST be replaced after theyhave been subjected to loading by occupants in acollision. Where replacement is necessary, theoriginal manufacturer’s components must be used.An audible warning and warning lamp areincorporated in the system.The warning lamp willilluminate for eight seconds when the ignition isswitched on regardless of seat belt usage.The audible warning will sound with an intermittenthigh and low note for four to eight seconds unlessthe driver’s seat belt is used.RR2 163E \\3. Remove the plastic cover and remove the boltsecuring the belt to the rear wheel arch.A single lap belt is provided for the occupant of thecentre rear seat.8’IREAR SEAT BELT.:: Remove and refitRemoving.,1. Detach the plastic cover from the upper seatbelt guide bracket and remove the securingbolt, plain and wavy washer and spacer.2. Remove the clip-on cover from the inertia reelassembly. Remove the securing bolt andspring washer and place the reel to one side.4. Withdraw the assembly.Continued37,.


‘.:CHASSIS AND BODYRANGE“*’ ROVER.’., ::”56‘,,(A’.,‘.: :RR2166E5. Working behind the rear seats, remove thebolt and plain washer and withdraw the buckleassembly.6. Centre lap strap only: working behind the rearseats, remove the bolts securing the lap strapand the buckle assembly and withdraw bothcomponents.Refitting.‘..:‘.,,I.. . . .,,.’,.:,,7. Reverse the removal procedure ensuring thatthe harnesses are not twisted. Finally tightenthe fixings to the correct torque (see sectionOC-Torque values).::,‘.’3:.:.....: ‘Y ‘.’38


;;;t: 1987CHASSIS AND BODYRR2102E. ...’FRONT SEAT BELTRemove and refit10. Disconnect the electrical connection andremove the bolt securing the buckle to theseat base.RemovingRefitting:.I1. Adjust the front seat to the mid-position.2. Disconnect the battery negative lead.3. Remove the seat cushion side trim panel - seeFront Seat - remove and refit, page 34, Section76.4. Remove the bolt, plain washer and spacersecuring the belt to the seat base.5. Remove the moulding from the adjustable seatbelt mounting.6. Remove the shouldered nut and spacersecuring the seat belt to the ‘B’ post.7. Remove the two screws securing the trimfinisher and release the finisher from the belt.8. Ease the door seal away and remove the lower‘B’ post trim casing.9. Remove the bolt and spring washer securingthe inertia reel assembly to the ‘B’ post andwithdraw the assembly.I 1. Reverse the removal procedure ensuring thatthe belt is not twisted. Finally tighten thefixings to the correct torque (see section06-Torque values).REVISED: APR. 87 39


CHASSIS AND BODYRANGElg8’ ROVERFRONT DOOR STOWAGE BINSRemove and refitRemoving1. Remove the seven fixings securing thestowage bin to the inner door trim pad.2. Withdraw the stowage bin.CLOVE BOX AND FLOOR MOUNTED CONSOLEASSEMBLYRemove and refitRemoving1.2.3.4.Disconnect the battery negative lead.Remove the four cross-head screws securingthe glove box liner to the glove box andwithdraw the liner.Disconnect the electrical leads to the rearpassenger cigar lighter.Maneuver the switch panel through the panelopening and place inside the glove box.NOTE: To enable the glove box/ consoleassembly to be removed, disconnect theparking, brake cable from the parking brakelever, to allow the lever to be raised to itsuppermost position.-. .5.Unscrew and remove the transfer gear knob.Refitting-- \3. Reverse the removal procedure.NOTE: Refer to Section 86 Electrical-Automatic gear selector ilhrmination panel,for full instructions on dismantling themain gear selector knob and illuminationpanel.6. Remove the main gear selector knob.7. Carefully pry the outer inset panel out of thefloor mounted console, disconnect theelectrical multi-plug to the inset graphicspanel, withdraw the assembly off the maingearbox selector.8. Remove the two bolts (with plain and springwashers) and ‘two screws (with plain washers)securing the floor-mounted console to thegearbox tunnel. .. .._.‘\i. . . ’40 . REVISED: APR. 67


CHASSIS AND BODY 76LOWER DASH PANELRemove and refitRemoving,': I'9.IO.Ease the assembly rear-wards to detach thesmall location tab at the front of the consolefrom the bottom of the radio housing.Maneuver the assembly from the parking brakeand gear levers and remove it from thevehicle.1.2.3.4.5.6.Disconnect the battery negative lead.Pry the louvre from the dash.Remove the two cross-head screws from thebottom of the panel located above the pedals.Remove the single cross-head screw from theside of the panel adjacent to the front doorcourtesy light switch.Remove the two cross-head screws from thetop of the louvre opening.Remove the single cross-head screw above therheostat switch.Refitting11. Reverse the removal procedure ensuring thatall electrical plugs are fitted securely andcorrectly. Arrange the electrical wiring beneaththe console to ensure it does not becometrapped between any joint faces.17. Lower the dash panel and disconnect theelectrical plug at the rear of the rheostatswitch and detach the bulb check unit fromthe spring clip.8. Remove the panel from the vehicle.Refitting9. Reverse the removal procedure.


:..::l-l 76 CHASSIS AND BODY1987 RANGEROVER‘. .‘.::.RADIO HOUSINGCENTRE DASH PANEL.a. '.,..’‘.‘.Remove and refitRemovingRemove and refitRemoving‘!‘,..‘.: ,,..,: .,.‘, ,,:...’.’‘.1. Disconnect the battery negative lead.2. Remove the glove box and floor-mountedconsole assembly.3. Remove the radio from the housing (SeeManufacturers instructions for removal andinstallation).4. Pry the differential lock warning lamp out ofthe radio console and disconnect the electricalleads.5. Remove the single screw securing the housingto the gearbox tunnel.6. Tilt the front of the housing upwards andmaneuver it away from the centre dash unit asfar as the cigar lighter electrical leads willpermit.7. Disconnect the leads from the rear of the cigarlighter and remove radio housing completewith lighter unit.1.2.3.4.5.6.7.8.9.10.11.12.\Disconnect the battery negative lead.Remove the lower dash panel to give accessto the single screw securing the side of thecentre dash and release the screw.Remove the glove box and floor-mountedconsole assembly.Remove the radio and radio housing.Detach the fuse box cover and remove thethree screws securing the main and auxiliaryfuse box body to the dash.Pull the five heater control knobs off theirlevers.Remove the two screws at the top of theheater graphics panel. Pull the panel awayfrom the dash and remove the illuminationbulbs from their locations.Withdraw the graphics panel.Pry the auxiliary switch panel away from thedash.Identify each switch multi-plug to aidreassembly, and disconnect them from theswitches.Release the three screws securing the topthe centre dash to the louvre dash panel.Remove the two screws securing the sidethe centre dash unit (front passenger side).ofof:, .Refitting8. Reverse the removal procedure ensuring theradio electrical leads do not bl-come trappedwhen refitting the radio to the housing.13. Maneuver the centre dash away from thelouvre dash and remove it from the vehicle., ..:>:. ,’1.;..‘. ‘.42 .


;g$; 1987CHASSIS AND BODYRefittingReverse the removal procedure ensuring thatall electrical multi-plugs are fitted correctly andsecure in their respective switches.Arrange all electrical wiring and harnesses sothat they do not become trapped betweenany mating faces.LOUVRE DASH PANELRemove and refitRemoving1. Disconnect the battery negative lead.2. Carefully pry the clock out of the dash,disconnect the electrical leads and remove thebulb and holder from its location.3. Remove the single screw securing the end ofthe dash panel located adjacent to thepassenger courtesy light switch.4. Carefully pry the four louvres out of theiropenings to gain access to the eight screwssecuring the louvre panel to the dashboard.5. Carefully pry the exterior mirror control switchout of the louvre panel and disconnect theelectrical multi-plugs, remove the remainingscrew at the top of the exterior driving mirrorcontrol panel opening.6. Remove the three screws securing the bottomof the panel to the centre dash panel. Removethe remaining three screws above the blowermotor trim panel.7. Withdraw the louvre panel from the vehicle.Refitting8. Reverse the removal procedure.43


CHASSIS AND BODY1987 RANGEROVERDASHBOARDRemove and refitRemovingService tools:18G1014 - Extractor for steering wheel18G1014.2 - Adaptor pins1. Disconnect the battery negative lead.2. Using service tool 18G1014 and 18G1014-2remove the steering wheel, secure the cruisecontrol cassette in position with adhesive tape.3. Remove the lower dash panel from below thesteering column.4. Remove the instrument binnacle (refer toinstrument binnacle remove and refit inSection 86-Electrical).5. Remove the glove box console assembiy.6. Remove the radio housing.7. Remove the centre dash panel.8. Detach the dashboard evaporator assembly,do not evacuate the air conditioning assembly,with refrigerant hoses still attached ease theassembly away from the bulkhead and lay onthe gearbox tunnel/passenger footwell area.(Refer to Section 82 - Air Conditioning for theremoval of the dashboard assembly).9. Remove the three nuts with washers retainingthe front passenger grab handle, accessiblefrom under the dashboard and withdraw thegrab handle.10. Remove the five nuts with washers retainingthe map tray base plate, accessible from underthe dashboard and withdraw the base platefrom the inset in the dashboard.11. Disconnect the side and centre air vent hosesfrom the heater unit.12. Maneuver the dashboard and withdraw it from ,the vehicle..‘.’,,.‘.,’


.-I’ro;;; 1987RefittingFRONT SPOILERCHASSIS AND BODY ri%ii,,”!”CAUTION: When refitting the dash componentsensure that all electrical leads are arranged insuch a manner as to prevent them becomingtrapped between any of the dash mating faces.13. Reverse the removal procedure ensuring thatthe dashboard locates on three brackets belowthe windscreen inner sealing rubber.14. Ease the sealing rubber over the top of thedashboard.The spoiler will reduce the vehicle approach angleby approximately 10”. Where the vehicle isexpected to perform on rough or hilly terrain, it isadvisable to remove the spoiler to prevent anydamage which may occur due to ground contact.The spoiler may be removed as follows:1. Disconnect the electrical connections at therear of both auxiliary driving lamps, accessiblethrough the front wheel arches.2. Remove the two screws (with spring washers)securing the centre of the spoiler.3. Remove the four nuts (with spring washers)located behind the front bumper above thedriving lamp pockets, accessible from beneaththe vehicle.4. Remove the two bolts, nuts and washerssecuring the outer edges of the spoiler to thecorners of the front fenders, located forwardof the front road wheels.5. Remove the spoiler complete with drivinglamps.--7-’Refitting6. Reverse the removal instructions.REVISED: SEPT. 87 45.:


CHASSIS AND BODY1987 KANCikROVERELECT’RICALLY OPERATED SUNSHINE ROOF17\SUNROOF ASSEMBLY1.2.3.4.5.6.7.8.9.10.11.12.Roof panelSunroof headlinerInsulation padRoof seals (front and rear)Sunroof headliner retaining clips (quantity - 6)Roof panel retaining screws (quantity - 6)Water channelWater channel connectorsSupport bracket-water channelSlide shoe-water channelMotor bracket/guide tube assemblyOperating motor13. Motor retaining screws14. Relay15. tower guide rails16. Front guide rails17. Slide mechanism18. Rear guide19. Pivot bracket20. Slide shoe21. Rear edge trim finisher22. Wind deflector assembly23. Wind deflector operating arms24. Support bracket (quantity - 6)4 6 ADDITION: SEPT. 87


;rv;; 1987CHASSIS AND BODYOPERATION’ The sunroof operates in a tilt and slide actioncontrolled by the rocker switch adjacent to theinterior roof lamp, with ignition switched ‘ON’.1. Depress front of switch to lift rear edge ofsunroof into ‘Tilt’ position.2. Depress rear edge of switch to close roof.3. Depress rear of switch to slide sunroof into‘Open’ position.4. Depress front of switch to slide sunroof into‘Close’ position.NOTE: The electric drive cuts out automaticallyin the closed, tilt and open positions. If theswitch is operated in the wrong direction in oneof these positions, press the switch once to resetand again to operate roof.EMERGENCY OPERATIONif the sun roof fails to operate, check the fuse andrenew if necessary. To close the roof in the eventof electrical failure carry out the followingprocedure.I. Lower the interior lamp mounting panel by,, ‘.Z... releasing two turnbuckles.2. Remove the emergency handle from thevehicle tool kit.3. Engage handle in motor drive spindle and turnto close roof.MAINTENANCEAt each service blow drain tubes out to ensure theyare not blocked or kinked. Blow upwards to clearrear drain tubes which are clipped to the rear mudflap supports. Blow downwards to clear front draintubes which run down each ‘A’ post and exit atback of engine bay.Annually: Clean sunroof opening thoroughly.Note: Where the vehicle is operated inextremely dusty conditions more frequentcleaning is recommended.OPERATING MOTOR, MICRO-SWITCH ANDRELAYNOTE: The motor drive spindle retaining nut isfactory set to the correct torque value. If theroof fails to operate, and drive failure issuspected, check the retaining nut torque andretighten to the correct value - 37 to 44 in lb(4.15 to 5.00 Nm).Remove and refitRemoving1. Ensure sunroof is fully closed. Disconnect thebattery negative lead.2. Remove interior lamp mounting panel byloosening two turnbuckles to gain access tothe motor.3. Disconnect two wiring connectors.4. Remove three securing screws and withdrawmotor.5. Remove securing screw and withdraw relay.6. Remove micro-switch from motor by drillingout securing rivets, if required.Refitting7. Secure new micro-switch using suitable nutsand bolts to replace rivets. Tighten nuts andapply a spot of paint to threads.8. Ensure motor is in the ‘park’ position, i.e. holeon driven gear aligned with drive spindle.9. Reverse removal procedure.10. Check operation of su.nroof in all positions.ROOF PANEL SEALSRemove and refitRemovingI. Position sunroof in the tilt position anddisconnect battery negative terminal.3. Unclip sunroof headliner from roof panel frontand slide the sunroof headliner back fully.3. Remove three roof panel fixing screws fromeach side and remove panel.4. Place the roof panel on a suitable surface toavoid damage, and remove both seals.ContinuedADDITION: SEPT. 87/REVISED: DEC. 87 4 7


”CHASSIS AND BODY1987 KANGtROVERRefitting 5.26Position front seal to front edge of panel,ensuring that there is an equal length of sealeach side of the centre point. Secure sealusing a rubber mallet.Position the rear seal on one side immediatelyto rear of the front seal. Secure seal aroundpanel edge ensuring a good fit aroundcorners. Trim off excess seal at joint with frontseal using suitable snips, ensuring that thejoint is closed.Refit the roof panel.SUNROOF ASSEMBLYRemove and refit- including roof panel, sliding mechanism, winddeflector,-motor- mounting bracket and guidetubes.A :.--;6,22 ? ?RemovingNOTE: lower vehicle headlining ONLY ifremoving motor mounting bracket and guidetubes. Note that the headlining is securedaround the roof opening using an adhesive tape.Remove edge trim and eight edge clips, carefullypeel back headlining to remove.7. Remove the slide and tilt mechanism completewith flexible drive cable from both sides. Donot strip these assemblies unless replacementparts are required..’1.2.3.4.5.6.Partially open sunroof rearwards and carefullyunclip sunroof headliner from roof panel front.Slide the sunroof headliner back fully.Position sunroof in the tilt position anddisconnect battery negative terminal.Remove three roof panel fixing screws fromeach side and remove panel.Remove motor securing screws and withdrawmotor.Remove the guide rail screws, seven each side.Remove the pivot bracket and remove frontguide rail.RR22@6EContinued--===G..‘.‘.’ ”.’:.,.,:: :,,”.‘.. .: :;O’..: :,. . . (.‘,48 ADDITION: SEPT. 87/REVISED: DEC. 87


po;f; 1987CHASSIS AND BODY:8. Unclip both wind deflector operating armsfrom rear mounting brackets. Remove armsfrom deflector, if required.RR2208E9. Remove seven fixing screws, and withdrawwind deflector.10. Remove lower guide rails and rear edgefinisher, seven screws, if required.11. Remove fixing screws from guide tubes, twoeach side. Remove five fixing screws andwithdraw motor mounting bracket.12. Pull sunroof headliner assembly forward andremove.RefittingNOTE: During assembly lightly lubricate allsliding parts using a silicon spray.13.14.15.16.17.18.19.20.21.22.23.24.Position motor bracket and guide tubeassembly. Fit and tighten the securing screws.Position right hand guide rail in rear retainingbracket, push reanvards fully and locateleading edge under drive cable opening.Repeat operation for left hand guide rail.Align fixing holes, and loosely fit screw inseventh hole from the front.Position finisher to rear edge of sun roofopening and secure using seven screws.Position sunroof headliner assembly into outerguide runners, and push fully rearwards.Lightly lubricate drive cables. Ensure that theslide and tilt mechanism is fully assembled.Push the cable fully into the right hand sideguide tube. Loop remaining cable and enterthe rear end into the right hand inner siderunner.Repeat operation 19. for left hand side. Pushboth assemblies rear-wards to take up slack inthe cables, and push a further 75 mm (3 in) tothe rear.Position both front guide rails, aligning withthe four forward holes. Secure with screws, donot tighten.Position both pivot brackets, fit but do nottighten fixing screws.Fit the wind deflector and fully tighten fixings.Position right hand operating arm in locatingslot in deflector. Secure opposite end in framebracket. Repeat for left hand side.Continued,‘-ADDITION: SEPT. 87 49


‘.CHASSIS AND BODY1987 RANGtROVER25. Pull right hand slide and tilt mechanismforward, align with pivot bracket and secure inposition using setting key. Repeat operationfor left hand side.RR2297E /’ 6 ’RR2327E‘.26.27.28.29.30.31.32.33.34.35.Tighten screws to guide rails, seven each side.Fit and secure relay.Ensure operating motor is in the park positioni.e. hole on driven gear aligned with drivespindle. Fit and secure to mounting bracket.Remove setting keys. Temporarily connectoperating switch and reconnect wiringincluding battery.Operate switch sequence to ‘tilt’ position.Position roof panel into roof opening andsecure with six fixing screws, do not tighten.Put roof into ‘closed’ position and adjust roofprofile. The panel profile should be 0.5 mmlow at forward edge, 1 mm high at rear edge.Tighten roof panel screws.Tilt sunroof, pull sunroof headliner forwardand locate rear brackets in tilt mechanism.Align front six clips and push to secure.Check operation of sunroof in all operatingmodes.36. Refit vehicle headlining. The headlining issecured around the sunroof opening with ‘3M’adhesive tape.37. Refit the eight edge clips as shown.38. Finally fit the edging finisher.50 ADDITION: SEPT. 87


PO;;: 1987CHASSIS AND BODYSUNROOF HEADLINER ASSEMBLYRemove, retrim and refitRemoving and retrimming1. Remove sunroof headliner assembly asdetailed in Sunroof Assembly - remove andrefit.2. Remove trim covering from frame assembly.Note that it is not normally necessary toremove the three pads and insulation padshown in illustration.3. If required: remove water channel byunclipping connecting arms. Drill out rivetssecuring connecting arms to frame.4. Secure connecting arms to frame usingsuitable rivets before retrimming frame.5. Retrim frame using a new headliner cover.inset shows section through frame indicatingwhere adhesive is applied. Dimension ‘A’should be radially constant.Refitting6. Refit sunroof headliner assembly andreassemble sunroof.ContinuedADDITION: SEPT. 87 / REVISED: MARCH 90


CHASSIS AND BODYKANGlilg8’ ROVERHEADLINING - 1987 MODEL YEAR IMPROVEMENTRemove and refit- \Removing1.2.3.4.5.6.7.8.9.10.11.12.Remove spare wheel from the vehicle.Remove the rear seat belt upper guidebrackets and inertia reel assemblies.Fold the rear seat backrest forward and reclinethe front seats as far as possible.Disconnect the battery negative lead.Remove the two roof lamp assemblies. (Lowerand remove the interior lamp mounting panelif the vehicle has a sunroof)Remove the rear view mirror and mountingbracket.Remove the two sun visors and centreretaining bracket.Remove the front and rear passenger grabhandles. Sunroof vehicles: Remove edge trimand eight edge clips from roof opening, andcarefully peel back headlining to remove.M’ith assistance support the front of theheadlining, while removing the two plasticretaining clips above the rear quarter lightglass.While the headlining is still being supported,remove the two plastic retaining clips securingthe rear end of the headlining, locatedadjacent to the upper tailgate hinges.Pull the headlining forward to clear the rearquarter trim. Lower the headlining anddisconnect the electrical leads from the roofmounted speakers.Remove the headlining through the tailgate.CAUTION: To assist removal tilt theheadlining at an angle. DO NOT flex theheadlining as damage may occur.Refitting8. Reverse the removal procedure. Sunroofvehicles: The headlining is secured around theroof opening with ‘3M’ adhesive tape. Refitthe eight edge clips and fit the edging finisher.See also Sunroof assembly, remove and refit.,_..- .,.j:. .’!52 . ADDITION: SEPT. 87 / REVISED: MARCH 90


FRONT DOOR - TRIM PANELRemove and refitRemoving1.2.3.Disconnect the battery negative terminal.Remove the screw securing the handlesurround.Remove the surround.I!I\5.6.Remove the two finisher buttons from thebottom of the door pull pocket to reveal thesecuring screws.Remove the screws and withdraw the pocketfrom the trim panel.RR23ki4E ’7. Using a taped screwdriver, carefully pry thetrim panel away from the door.NOTE: Support the trim panel while thespeaker leads are disconnected.4. Carefully pry the sill locking button surroundfrom the trim panel.8. If necessary the stowage bin front panel canbe removed by releasing the screws at the rearof the trim panel.Refitting9. Reverse the removal procedure.ContinuedADDITION: SEPT. 88 5 3:.


76 BODYRANGElg8’ ROVERFRONT DOOR LOCK, OUTSIDE AND INSIDEDOOR RELEASE HANDLESRemove and refitRemoving1. Remove the interior door release handle bezeland sill locking button bezel.2. Remove the two screws from the bottom ofthe door pull pocket remove the pocket andprise the door trim panel from the door.Disconnect the electrical leads to the doorspeaker and remove the plastic vapor barriersheet.Remove the window lift motor. (Refer to theelectrical section in main Workshop Manual).4. Remove the door glass and regulator. (Refer todoor glass and regulator remove and refit inmain Workshop Manual).5. Remove the door lock actuator. (Refer toelectrical section in main Workshop Manual).6. Disconnect the control rod from the keyoperated lock by releasing the metal clip atthe bottom of the rod.7. Disconnect the control rod from the outsidedoor release handle by pulling it out of theplastic ferrule.8. Disconnect the control rod connectorbetween the inside door release handle andthe door lock by releasing the metal clip andpulling one of the control rods out of theplastic connecting block. This is accessiblethrough the small centre cut - out in the doorpanel. (The control rod also passes through aguide bracket on the inside of the inner doorpanel).9. From inside the door panel push out the smallpin which secures the quadrant to the innerdoor panel. Push the quadrant out of thepanel.10. Remove the two screws securing the silllocking button to the door. manouver the sillbutton and remove it from the control rod.11. Release the door lock by removing the twocountersunk screws from the door edge andthe single screw with shakeproof washer onthe inner door panel.,5 4 ADDITION: SEPT. 888, . .


12. Withdraw the lock through the lower rear cut - 3. Disconnect the heaters electrical wiring at theout on the inner door panel.multiplug.4. Remove heater retaining bracket screw.NOTE: If necessary the following items can 5. Remove T? clip and colored cam link frombe removed.end of barrel assembly.13. Remove the two nuts (with shakeproofwashers) and retaining bracket securing theoutside release handle to the outer doorpanel, accessible through the upper rear cut -out on the inner door panel.14. Carefully detach the door release handle fromthe outer door panel.15. Remove the two screws securing the insidedoor release handle to the inner door panel.16. Withdraw the handle from its location withhalf of the connecting rod attached.Refitting17. Reverse the removal procedure items 1 to 16.Caution: Ensure the loose barrel assemblyremains in position, to avoid components fallingapart.6. Remove heater retaining bracket, completewith de-icing element, switch and wiringassembly.Refit7. Hold de-icing element in positiori and fitheater retaining bracket assembly.8. Reverse removal instructions 1 to 5.9. Recode the radio.ADjUSTMENT - FRONT DOOR LOCK ANDHANDLE ASSEMBLYNOTE: When refitting the door glass frame,ensure that it is positioned to suit the dooropening before fully tightening the framesecuring bolts.HEATED FRONT DOOR LOCK ASSEMBLY - 1991MODEL YEARRemove and refitRemoveInside door release handle to lock1.2.Refit the inside door release handle bezelbefore any adjustment is made, allowing thehandle to be set for the correct operatingposition.Rotate the spring tensioned nyloc nut at thedoor lock clockwise or counter - clockwise toshorten or extend the operating length of therod as required.1.2.Disconnect battery negative lead.Remove outside front door handle assembly.RR230 1 EADDITION: SEPT. 88 / REVISED: SEPT. 90 5 5


KANGE1989-91 KOVEKOutside door release handle to lock3. Disconnect the connecting rod at the rear ofthe outer door release handle by releasing thethe rod from the plastic ferrule, rotate the rodclockwise or counter - clockwise to shorten orextend the operating length, refit the rod tothe ferrule.NOTE: Door release should occur beforethe total handle movement is made toprovide a small overthrow movement.REAR DOOR - TRIM PANELRemove and refitRemoving1.2.3.Disconnect the battery negative terminal.Remove the screw securing the handlesurround.Remove the surround.5. Remove the two finisher buttons from thebottom of the door pull pocket to reveal thesecuring screws.Remove the screws and withdraw the pocketfrom the trim panel.Using a taped screwdriver, carefully pry thetrim panel away from the door.Disconnect the electrical plug from thewindow lift switch.Remove the window lift switch by pushingfrom behind the trim panel.5.Refitting10. Reverse the removal instructions..RR24764. Pry the door locking button surround from thetrim panel.!.’5 6 ADDITION: SEPT. 88 I REVISED: SEPT. 90:’.L,..(


,’ .REAR DOOR LOCK, OUTSIDE AND INSIDE DOORRELEASE HANDLESRemove and refitRemoving7.2.3.4.5.6.7.Ensure the window is fully closed position anddisconnect the battery negative terminal.Remove the interior door handle surround, prythe window lift switch from the trim panel anddisconnect the electrical multi - plug.Pry the sill button from the trim panel.Remove the two screws from the bottom ofthe door pull pocket accessible after removingthe two buttons and detach the trim panelfrom the door panel. Remove the plastic vaporbarrier sheet.Disconnect the control rod from the insidedoor release handle by pulling the rod out ofits location at the door lock.Disconnect the sill locking control rod fromthe door lock by releasing the metal clip.Disconnect the control rod from the outsidedoor release handle by pulling it out of theplastic ferrule.8. Release the door lock by removing the twocountersunk screws from the door edge andthe single screw (with shakeproof washer) onthe inside of the door. Retrieve any spacingwashers which may be fitted between theinner door panel and lock.9. Withdraw the lock through the upper rearopening in the inner door panel.NOTE: If necessary the following items canalso be removed.70. Remove the two nuts (with shakeproofwashers) and retaining bracket securing theoutside door release handle which areaccessible through the upper rear cut - out onthe inner door panel.71. Carefully detach the outside door releasehandle from the outer door panel.72. Remove the two screws (with plain washers)securing the inside door release handle to theinner door panel.13. Withdraw the handle from its location with theconnecting rod attached.ContinuedIiADDITION: SEPT. 88 57‘. _


1989 RANCEROVER14. Remove the two screws securing the silllocking button to the inner door panel anddetach the sill button from the bellcrank.Sill locking bellcranks15.16.17.RefittingUsing a small screwdriver, or 3.175 mm (0.125in) diameter rod, press the plastic locking pinsthrough the respective square inserts in theinner door panel, until they can be retrievedfrom inside the door.Release the bellcranks from the inner doorpanel and unhook the respective connectingrods.Withdraw the bellcranks from the inner doorpanel.NOTE: When refitting the bellcranks thelocking pins are entered into the squareinsert from outside and pressed in flush.18. Reverse the removal procedure items 1 to 17.NOTE: When refitting the door glass frame,ensure that it is positioned to suit the dooropening before fully tightening the framesecuring bolts.ADjUSTMENT - REAR DOOR LOCK AND HANDLEASSEMBLY - 4 Door modelsOutside door release handle to lock1. Disconnect the short offset connecting rod atthe rear of the door outer release handle,rotate the rod clockwise or counter -clockwise to shorten or extend the operatinglength of the rod as required.NOTE: Door release should occur beforethe total handle movement is made toprovide a small overthrow movement..I5 8ADDITION: SEPT. 88


:. .,+x..ASYMMETRIC SPLIT REAR SEAT - LOCKINGMECHANISMNOTE: 1989 Model Year vehicles have a revisedseat locking mechanism which incorporates apush button release in place of a finger liftbutton. The revised latch and striker give theseat an improved positive location.Remove and refitRefitting13. Refitting is a reversal of the removal procedurenoting that when the seat release button isscrewed onto the operating rod there must bea gap of 5 - 8 mm (0.196 - 0.312 inch)between the head of the button and lip of thetrim covering after the button has beendepressed..,.Removing1.2.3.4.5.6.7.Depress the seat release button and fold theseat back forward.Unscrew and remove the seat release button.Pry out the two trim buttons securing the trimcovering to the latch tower.Manouver the trim covering from the tower.Remove the three screws securing the latch tothe tower, noting that access to the singlescrew is gained through the hole in the frontof the tower.Retrieve the latch from the opening at the rearof the tower. If necessary retrieve the singlescrew.The operating rod can be removed from thelatch by releasing the rod at the plastic clip.ContinuedRR24OlEADDITION: SEPT. 88 59


RANGElg8’ ROVERENGINE UNDERTRAYRemoval of engine under-tray fitted to 1989 modelyear vehicles is necessary when changing the oilfilter. Remove will also facilitate attention to engine,cooling system and steering components.Remove and refit1. Disconnect battery negative lead.2. Remove three screws, securing under-tray tospoiler.3. Remove two screws, one each side, securingrear of under-tray to chassis mounting brackets.4. Remove under-tray by carefully flexing to clearrear mountings.5. Removal of one or both rear mountingbrackets may be necessary, for example, whenremoving steering box. Remove the nut andwasher from the chassis bolt.6. Withdraw the undertray mounting bracket.Refitting7. Reverse the removal procedure.‘\I.;.I.I”..T’ :y,.60 . ADDITION: SEPT. 88


:.PO:;; 1989CHASSIS AND BODY 76 r-lFRONT DOORAdjusting..,.,...’Remove, refit and adjust.Removing1. Disconnect the battery negative lead.2. Open the door to be removed.3. Remove the trim panel from side of footwellby carefully levering under the trim and prisingout the two plastic clips.12. Adjust the door by means of shims betweenthe hinge and door to move the door forwardor rearward in the opening.13. Loosen the six Torx screws securing thehinges to the door to adjust the door up anddown or in and out of the opening. Retightenthe screws to the specified torque values.14. The door lock striker can be adjusted byloosening the striker and moving it in theappropriate direction or adding andsubtracting spacing washers between thestriker and ‘8’ post.\ \ !J I\!!(‘i ‘i’ i \\ 1RR 1588MRR2685M4. Locate and disconnect all door wiring plugs.5. Disengage the grommets either side of ‘A’post and feed wiring out.6. Drive out the roll pin from the door checklink.7. Remove ‘C’ clips from grooves in hinge pins.WARNING: Instruction 8. MUST BE carriedout with assistance.8. Carefully lift the opened door off the hingepins.Refitting9. Reverse the removal procedure. Renew the’C’clips if worn or distorted.10. With door fully open reconnect wiring plugsensuring they are located above the trimpanel.11. Check the operation of the door and lock. Ifnecessary, adjust the door and striker plate.15. Note: If it is necessary to remove hinges from‘A’ post they should be refitted in exactly thesame position using the same thickness ofshims.REAR PASSENGER DOORRemove, refit and adjust.Removing1. Disconnect the battery negative lead.2. Remove wiring grommet from the ‘B’ post.3. Withdraw the door wiring plugs from the ‘B’post and disconnect them.4. Remove the two bolts securing the checkstrap to ‘B’ post.ADDITION: MAY 89REVISED: SEPT. 89 61


l-l 76 CHASSIS AND BODYRANGEls8’ ROVER5. Remove ‘C’ clips from grooves in the hingepins.WARNING: Instruction 6. MUST BE carriedout with assistance.6. Carefully lift the opened door off the hingepins.ICOWL PANELRemove and RefitRemoving1. Disconnect the battery negative lead andremove the hood.2. Remove the wiper arms and two nuts securingthe wheel boxes to the cowl panel andremove the two sealing rubbers.3. Remove the two cross-head screws retainingthe panel to the ‘A’ post mounting bracketslocated above the front door hinges.!i;5RR2683M \Y IrllRefittinghh7. Reverse the removal procedure. Renew ‘C’clips if worn or distorted.8. Check the operation of the door and lock. Ifnecessary, adjust the door and striker plate.4. Remove the nine cross-head screws securingthe front of the cowl panel.5. Remove the four bolts with spring and plainwashers securing cowl panel to front fendersaccessible from the front of the cowl panel.Adjusting9. Adjust the door by means of shims betweenthe hinge and door to move the door forwardor rearward in the opening.10. Loosen the six Torx screws securing thehinges to the door to adjust the door up anddown or in and out of the opening. Retightenthe screws to the specified torque values.11. Adjustment to the door striker is identical tofront doors.12. Note: If it is necessary to remove hinges from‘B’ post they should be refitted in exactly thesame position using the same thickness ofshims.62 ADDITION: MAY 89lREVISED: SEPT. 89


;“d”z; 1989CHASSIS AND BODY6. With assistance place a tube over each of thehinges and lower to enable the cowl panel tobe fed over the hinges, gradually return thehinges to their upright position.RefittingWARNING: Gradually let the torsion barspring tension return the hinges IO theirupright position to prevent the possibilityof personal injury or damage to the vehicle.7. Reverse the cowl panel removal instruction.8. Using a soft blunt implement ease thewindscreen rubber up onto the top of thecowl panel.SILL FINISHERRemove and refitRemoveI. Remove nut and washer from underneath thefront of sill finisher.2. Using a drift tap through the centre piece ofthe ten ‘Recut’ fixing rivets.3. Carefully pry out the Recut rivets and removethe sill finisher.FRONT WHEEL ARCH LINERRemove and refitRefit4. Reverse the removal procedure, renewing theRecut rivets and ensuring the metal tube insertis refitted into the sill finisher where the boltgoes through.Remove1. Remove the bolt and washer securing the rearlower edge of the liner.2. Carefully pry out the centre studs of the eightplastic clips spaced around the liner.3. Carefully pry out the plastic clips.4. Remove the liner.Refit5. Reverse the removal procedure renew theclips as necessary.ADDITION: MAY 89/REVISED: MARCH 90 6 3


CHASSIS AND BODY1990 RANGEROVERa IfPI Iwwi8 1~~sADDITION: SEPT. 99I13


CHASSIS AND BODYCHASSIS FRAME - 1990 Model YearI ‘_Alignment check - RR2718EAA Wheelbase reference dimensionBB Centre line of front axlecc Centre line of rear axleDD Frame datum lineEE Side member datum lineFF Datum line2345678910111213A13814151617181920212223242526272829303132Diagram referenceFrame datum to underside of cross-memberReference dimensionTo face of boss (both sides)Check figureReference dimensionReference dimension2540,OOmillimeters264,525 2 I,27150,80266,70 + 2.54237.74 _?I I,27327.81 2 2.54979,942179,73 f 2,54291,74 + 2,54707,96 + 1,541468,49 + 2.541025,27 t 2,54338,84 + 2,54222.25 & 2.54252,904 + 2.54024,92935,43 + 2,54838,2 + 0,38630.94 + I,27344,17 + I,27485,77 + 2,54405.77 + 2,54028,68 + 0,38129.03 _f 2,542479.45 + 0,251290,34 + 0,381657,04 + 0,382598,44 + 0,3879,09 + 0,38465‘48 + 2,541398,88 +- 0,38368,30 +- 2,54317,50635,00100.0inches10.400 + .0505.93710.500 + .I009.360 + .05012.906 + .I0038.5885.816 -f .I0011.486 r. ,10027.872 + .I0057.815 f- ,10040.36 + .I0013.34 + .I008.750 + .I009.960 2 .I0032.47736.828 + .lOO33.000 + .01524.840 + .05013.550 + .05019.125 2 .lOO19.125 + .lOO32.625 + .0155.080 + .I0097.616 + .OlO50.800 -f. .01565.238 k .015102.301 + .0153.114 + .01518.326 + .lOO55.074 + .01514.50 + .I0012.5025.00ADDITION: SEPT. 89 65,,


CHASSIS FRAMEDiagram reference millimeters inches.-.ISECTION W - W33 Frame datum line DD3435155.91 + 1,27990,6 k 0,386.14 2 .05039.00 + .015SECTION X - X36 Frame datum line DD3738488,95 + 2.54295.27 + 2,5419.250 + .lOO11.625 + .I00SECTION Y - Y.’98 Frame datum line DD4041660,40 + 0,2580,39 + I,2726.00 2 .'OlO3.187 + .050SECTION 2 - Z42 Frame datum line DD43444580.39 + I,27660,40 + 0.259.53 +. 2,543.165 + .05026.000 + .OlO0.375 + .I00.,‘,‘. .’.’,..’.:I.:,, ”‘.: .’;--.!2’ADDITION: SEPT. 89,,:.


CHASSIS AND BODY‘. ,,.I..GLASS SUNROOF 1991 MODEL YEAROperationThe sunroof operates in a tilt and slide actioncontrolled by a rocker switch near the interior lamp.A drive motor and control unit is located behindthe switch and interior lamp panel. The controlunits function is to stop the drive motor at the fulltilt and slide positions.The removal and refit of the sunroof assembliesshown can be carried out without removing thecomplete sunroof assembly.GLASS SUNROOF ASSEMBLY.Remove refit and adjustRemove1. Open the sunroof to the tilt position.2. Remove the two mechanism covers. Sliderearwards to disengage from their location andlift out.3. Remove two screws from each side as shown.4. Remove glass sunroof.8. Check the height of the sunroof panel againstthe roof aperture. The trimmed edge of theglass sunroof should stand approximately lmmproud of the roof aperture.9. Adjust by releasing the four screws andmoving the sunroof up or down as required.Tighten the screws.10. Fit the two mechanism covers.11. Fully check the sunroof operates correctly.SUNROOF WIND DEFLECTOR ASSEMBLYRemove, refit and adjustRemove1. Open sunroof.2. Remove the two screws accessed through theslot in the deflector3. Remove the wind deflector assemblyRefit4. Replace the wind deflector assembly5. Fit the two screws firmly but do not tighten.AdjustNote: Adjustment and attachment of thedeflector is by the same two screws.Refit and adjust5. Replace the glass sunroof6. Fit the lour screws firmly but do not tighten.7. Close the sunroof6. Adjust the wind deflector rearwards orfonvards into the position shown. At the sametime adjust the height A’ to 20mm by movingthe slotted metal strip rearwards or forwards.Tighten the two screws.7. Ensure the deflector does not catch the frontedge of the roof aperture when operated.8. On completion fully check that the sunroofoperates correctly.ADDITION: SEPT. 90 67


RANGElgg’ ROVERManual operation.If the sunroof fails to operate by electricalmeans the sunroof can be opened or closedmanually with the key provided.Remove the two tumbuckles to access thesunroof motor spindle located behind theswitch plate.Engage the key into the motor spindle andturn to open or close the sunroof panel.On completion of manual operation the motorspindle MUST BE TURNED BACK HALF ATURN TO ENSURE ENGAGEMENT TO THEELECTRICAL DRIVE MOTOR.4. Release the front of the headlining sufficientlyto access the motor drive assembly andcontrol unit.5. Disconnect the two multiplugs from thecontrol unit to the motor drive unit and to themain harness.RefitRemove the three screws securing the motordrive assembly.Remove the motor drive assembly.To remove the control unit undo the fixingscrew. Lower then move the control boxinwards to release from mounting.Inspect the motor drive assembly and controlunit for wear and damage, renew as necessary.MOTOR DRIVE ASSEMBLY AND CONTROL UNITNOTE: The following servicing of the sunroofassembly can be carried out without removingthe complete sunroof assembly.Remove and refitRemove1. Fully close the sunroof then disconnect thebattery negative terminal.2. Turn to release the two turnbuckles to accessthe motor drive assembly and control unit,located behind the switchplate.3. Remove the switchplate and disconnect thetwo multiplugs from the switch and courtesylight.10. Refit the motor drive assembly ensuring themetal insert is fitted.CAUTION:The motor drive assembly gear will notmesh correctly with the drive cables if the metalinsert is NOT refitted.11. Refit the control unit.12. Check timing of the control unit to sunroof. AV’shaped notch should be visible through theslot in the control unit when the sunroof is inthe fully closed position.13. Reverse the removal instructions 2 to 5.14. Fully check the sunroof operates correctly.Recode the radio..6 8 ADDITION: SEPT. 90


I: ‘.’ :.:.::GLASS SUNROOF COMPLETE ASSEMBLYRR2914M_.:I’-,’:.,Remove and refitRemove1. Fully open the sunroof rearwards thendisconnect the battery negative terminal.2. Remove the switchplate and disconnect thetwo multiplugs from the switch and courtesylight3. Remove the headlining completely from thevehicle4. Remove the four clips and disconnect thedrain tubes5. Disconnect the multiplug from the control unitto the main harness.6. With assistance remove the eight nuts andwashers and two bolts. Lower the completesunroof assembly to enable it to be removedthrough the rear of the vehicle.Refit7. Manually operate the sunroof to the fullyclosed position.On completion of manualoperation the motor spindle MUST BETURNED BACK HALF A TURN TO ENSUREENGAGEMENT TO THE ELECTRICAL DRIVEMOTOR.8. With assistance lift the complete sunroofassembly to the roof panel.9. Locate and fit loosely the eight retaining nutsand washers and two bolts.10. Ensure the closed sunroof now fits equallypositioned in the roof panel aperture. Tightenthe retaining nuts and bolts, recheck fit.11. Reconnect the electrical multiplugs to themain harness and sunroof switch.12. Fully check the sunroof operates correctly andleave in the open position.13. Disconnect the sunroof switch14. Fit and secure the drain tubes with retainingclips.Water test to ensure a watertight seal.15. Fit the headlining and sunroof trim.16. Reconnect electrical multiplugs to sunroofswitch and interior light then fit switchplate.17. Close glass sunroof and draw sunshade.Recode the radio.ADDITION: SEPT. SO


76 CHASSIS AND BODYRANGElggl ROVERSLIDE AND GUIDE CHANNEL ASSEMBLIES ORSUNSHADE PANEL. ‘.RR2929M \\Remove and refitNOTE: The following servicing of the sunroofassembly can be carried out without removingthe complete sunroof assembly.The sunshade panel is removed by releasing,either the left or right slide and guide channelassembly, instructions 1. to 12.6. Move the tilt slide forwards until the locationcam has reached the position it wouldnormally locate into the locator block.Manually adjust the cam outwards to allow thetilt slide to pass and to attain the full tiltposition.Remove1.2.3.4.5.Remove glass panel assembly.Remove sunroof wind deflector assembly.Remove rear crossmember drainchannel.Move the tilt slide rearwards until the locationcam is clear of the locator block.Remove the locator. block.RR2930MRR2929M7.8.9.10.The drive cable end is now accessible.Disconnect drive cable from the slideassembly.Push the tilt slide rear-wards reversinginstruction 6.Push complete slide assembly rearwardsapproximately 2”.Remove front end stop and the attachingscrew from centre of guide channel. “..’ : Ii7 0 ADDITION: SEPT. SO.,..:


;“d”g 1991CHASSIS AND BODY‘.11. Push guide channel assembly out sideways to 2. To check timing of the control unit when theI release guide channel from the roof panel. glass sunroof panel is removed. A V’shaped\. 12. Slide the sunshade panel forward and lift out notch should be visible through the slot in theof runner to remove.control unit when the sunroof tilt mechanismis in the position shown.Continue for removal of slide and guidechannel assembly.13. With the aid of a flashlight directed betweenthe roof panel and sunroof assembly. Observefor reassembly the guide channel rear springfixing point.14. Pull the guide channel forward to release fromthe rear spring fixing point. Remove the guidechannel asemblyRefit15. Reverse the removal instructions16. Fully check the sunroof operates correctly.TIMING OF CONTROL UNIT TO SUNROOFOPERATION.* ‘. :The timing of control unit to sunroof operation willbe disturbed:-If the sunroof position is altered when the controlunit is removed.Or the control unit is removed and the control unitgear is moved manually.1. To check timing of the control unit to sunroof.A V’shaped notch should be visible throughthe slot in the control unit when the sunroofis in the fully closed position.6327hl.-7 1


,,:: ,.; ,,. :


,.’HEATING AND VENTILATION:3 :.‘,.HEATER AND AIR CONDITIONING CONTROLSRemove and refitRemoving13. Air conditioning/fresh air/ recirculatingswitch: remove fixing screws and withdraw the-- switch.‘.’:., ”,;1.2.3.4.5.Disconnect the battery negative lead.Remove the transmission lever surround andradio housing.Remove the lower dash panel.Remove the centre dash unit.Disconnect the electrical leads from thethermostat, fan speed and recirculate/fresh airswitches.Disconnect the relay rod from‘SCREEN-CAR’ lever.Disconnect the relay rod from the ‘VENT’lever.Disconnect the control cable from the side ofthe heater unit.Refitting-\ A714. Reverse instructions 5 to 13.15 Check that the control levers give fullmovemenr IO the flaps. If necessary, adjust atthe relas rod or cable end fixings.16. Reverse instuctions 1 to 4..RECIRCULATING/FRESH AIR SOLENOID SWITCHLVACUUM UNIT (recirculating/fresh air flap)ove and refitDisconnect the battery negative lead.Remove the transmission lever surround.Remove the radio mounting console.Remove the centre dash unit and the lowerdash panel.Disconnect the electrical leads to thesolenoid.Continued1:..’


RANGE80 HEATING AND VENTILATION lg8’ ROVER6. Disconnect the two vacuum hoses.7. Remove the solenoid fixings and withdraw thesolenoid.8. Vacuum unit: remove the vacuum hose fromthe vacuum unit.9. Remove the actuating rod securing clip.10. Remove two fixing nuts and washers andwithdraw the vacuum unit.Refitting11. Reverse the removal procedure.VACUUM RESERVOIR (recirculating/fresh air flap)Remove and refitRemoving1. Disconnect the battery negative lead.2. Remove the two vacuum hoses.3. Looser. the reservoir fixings.4 Withdraw the vacuum reservoir.HEATERUNITRemove and refitRemoving1.2.3.4.5.6.Disconnect the battery negative lead.Drain the cooling system.Disconnect the water inlet hose from theheater.Disconnect the water outlet hose from theheater.Working inside the vehicle wrthdraw the lowerdash and remove the screws securing thelower edge of the centre console.Remove the six screws securing the loweredge of the louvre panel to the console andevaporatot case..-.RR2123ERi2187ERefitting5. Reverse the removal procedure. Note that thelarger diameter hose, from the inlet manifoldfits the inlet marked VAC on the reservoir.7. Remove the heater control panel and knobsfrom the centre console.8. Remove the centre console.9. Carefully pry out the four air vents.10. Remove the screws securing the evaporatorplenum and louvre panel to the dash toppanel.11. Withdraw the thermostat sensor from the finsof the evaporator, and pull the sensor pipeclear of the evaporator assembly.12. Disconnect the electrical connectors at therear of exterior driving mirror control switchesand clock, and withdraw panel clear of thedash.13. Remove the screws securing the lower rightmounting bracket.2 . REVtSED: JULY 88


E;;f; 1987IHEATING AND VENTILATION 80HEATER FAN MOTORRemove and refitRemoving1. Remove the heater unit.2. Disconnect the multiplug and remove the redand black leads from the multiplug.3. Disconnect the air cooling hose.14.15.16.Support the evaporator case and remove thetwo nuts securing the case and reinforcingstrip to the upper mounting bracket.Remove the cover bracket and carefully lowerthe evaporator assembly to the floor of thevehicleDisconnect the six hoses from the heater unit.RR2090E^17. Disconnect the electrical leads from the heaterunit at the multiplug.18. Remove the four heater mounting bolts.19. Remove the heater unit.Refitting20. Check that the seal for the fresh air intake is inplace on the back of the heater unit.21. Check that the seal for the heater core is inplace on the hoses.22. Reverse 1 to 19, ensuring that all openings areadequately sealed against the ingress of dustand moisture.NOTE: Refer to Air Conditioning Section 82 forfull instructions regarding evaporator assemblyremoval.4. Remove five screws and withdraw the fan andmotor assembly.5. Loosen two set screws securing the fan to themotor shaft and remove the fan.6. Drill out three pop rivets and remove the fanmotor.Refitting7.8.9.10.Locate the fan motor and secure using suitablepop rivets.Engage the fan motor shaft into the boss onthe fan and secure the set screws.Locate the fan motor in position, engaging thefan shaft into the bearing.Hold the fan motor firmly in position andcheck that the fan rotates freely. If necessary,adjust the position of the fan on the motorshaft.ContinuedREVISED: jULY 883, ’1’. .:.;


HEATING AND VENTILATIONRANGtlg8’ ROVER.I11. Align the air cooling hose connection and refitthe five screws securing the fan motorassembly.12. Connect the air cooling hose.13. Reconnect the electrical leads.14. Refit the heater unit.FAN MOTOR RESISTANCE UNITHEATER CORERemove and refitRemovingI. Remove the heater unit.Remove and refitRemoving1.2.3.4.5.6.7Remove the heater unit.Disconnect the electrical leads at themultiplug.Disconnect the air cooling hose.Remove the fan motor and fan assembly.Remove the electrical leads from themultiplug.Drill out the two pop rivets securing theresistance unit.Withdraw thp resistance unit complete withleaas.2.3.4.5.6.7.Remove the fixings from the cam bracket forthe fresh air flap, and move the cam andbracket assembly aside.Remove the lock-washers from the four flapRefittingshafts.Remove all the drive screws from the left handside cover.Withdraw the left hand side cover completewith the fresh air flap.Withdraw the heater core complete with seals.Withdraw the seals from the heater core.. .8. Apply Bostik sealing compound around theflange of the left hand side cover.9. Reverse 1 to 7.Refitting8. Reverse 1 to 7.4 . REVISED: JULY 88


HEATING AND VENTILATION l-l 80; :HEATER UNIT 1990 MODEL YEARRemove and RefitHEATER AND AIR CONDITIONING CONTROLSRemove and refit‘.:To remove and refit the heater unit, refer toexisting instructions ignoring reference to thethermostat sensor. In addition the followingelectrical controls from the heater to the airconditioning unit need to be disconnected onremoval and connected on refit:-1. The electrical connector from the heatercontrols to the electric thermostat, sited at therear of the evaporator housing.2. The vent lever microswitch at the multiplug.RECIRCULATING/FRESH AIR SOLENOID SWITCHAND VACUUM UNIT (recirculating/fresh air flaps)Remove and refitRemove1. Disconnect the battery negative lead.2. Remove the transmission lever surround.3. Remove the radio mounting console.4. Remove the centre dash unit and the lowerdash panel.5. Solenoid switch: disconnect the electricalleads to the solenoid.6. Disconnect the two vacuum hoses.7. Remove the two screws and withdraw thesolenoid.0. Vacuum unit: remove the vacuum hose.9. Remove the actuating rod securing clip.10. Remove two retaining screws and remove thevacuum unit.Remove1.2.3.4.5.6.7.8.9.10.11.12.Disconnect the battery negative lead.Remove the transmission lever surround andradio housing.Remove the lower dash panel.Remove the centre dash unit.Disconnect the electrical plugs from the fanspeed and recirculate/fresh air switches.Fan speed switch: remove fixing screws andwithdraw the switch.Air conditioning / fresh air / recirculatingswitch: remove fixing screws and withdraw theswitch.Potentiometer: disconnect the electricalconnector to the electronic thermostat sited atthe rear of the evaporator housing.Prise the wrre cable connection from the heatcontrol leverRelease tne potentiometer from its location.Remove potentiometer with connecting arm toheat control lever. Withdrawing the attachedelectrical leads through the gommet.Microswitch: disconnect the multiplug, liftvent lever, remove the two retaining clips andcarefully withdraw the microswitch.AR2808MRefit.’Refit11. Reverse the removal procedure.13. Reverse removal instructions. Check thesatisfactory function of the controls beforefitting dash and trim panels.... .2’.::.1...:.., ,... ;: :::ADDITION: SEPT. 89 I REVISED: MARCH 905.;... :


:HEATING AND VENTILATIONRANGElggo ROVERHEATER FAN MOTOR, ROTOR AND RESISTANCE UNIT.Remove and refit .*‘. ’6,‘,,,,,, .’,. :Remove. ..‘>.C I.‘. .,.._:.1.2.3.4.5.6.7.8.9.10.Remove the heater assembly.Remove the left duct to footwell outlet.Mark the position of vent control rod forreassembly. Disconnect by carefully prisingopen the plastic clip.Disengage the grommet from side cover.Remove the six screws retaining the sidecover.Remove the vacuum unit to air flap linkage.Withdraw the side cover to expose the electricwires to the fan motor and resistance unit.Release the resistance unit by tensioning backthe metal mounting straps.Remove the side cover feeding the electricalleads and the multiplug through the hole.Remove the ten spring clips, three circlips andthe two screws that secure the halves of theheater casing together. Ensure all fixings andfoam gaskets are removed.::.‘:?a:.: : _.6 ADDITION: SEPT. 89 I REVISED: MARCH 90


; : , . (po;g 1990HEATING AND VENTILATION 80 .11. Position the flap (A) as shown, prise and slide12.13.14.its lower edge through the gap betweenmotor housing and outer case. Whileseparating each half of the heater casing.Note the location of the air flap pivots, forreassembl).The motor assembly is held into the left halfof the casing by two plastic tabs, locate ,andprise them away from the motor.Note for reassembly the position and layout ofthe electrical wiring. Then withdraw the motorassembly including attached wires andresistance unit from its housing.Refit15.16.17.18.19.20.21.22.23.24.2526.27Feed the wiring and resistance unit throughthe motor housing and fit the motor assembly.Ensure the wires are positioned correctly, toavoid entangling the rotor, and the plastic tabslocate to secure the motor.Mark a white spot on the end of each air flappivot to be reassembled into the heatercasing.Offer the heater casing halves together. Ensurethe flap (A) is positioned to reverse instruction11.Point the remainmg air flap pivots in thedirection of their location.Locate and slot into the left casing the heatercontrol panel assembly. Examine closely toensure that both fixings engage and slide intotheir housing.Slowly and firmly push the casing halvestogether checking that all components arealigned. Any solid resistance felt suggests acomponen; ic. n o t locating correctlv. Rectifvand contmue until ine casing halves aretogether.Refit all of the fixings holding the heatercasing halves together.Reverse removal instructions 4 to 9.Connect the rod to the vent control lever toits marked position.Check all controls operate and flaps sealagainst the heater casing.Refit the left duct to footwell outlet.Renew the foam gaskets.Refit the heater assembly.RR2826M,A :.,>‘..IADDITION: SEPT. 89 / REVISED: MARCH 907*:,:.


HEATING AND VENTILATIONRANGElggo ROVERHEATER CORERemove and RefitRemove1.2.3.4.5.6.Remove the heater assembly.Remove the left duct to footwell outlet.Mark the position of vent control rod, forreassembly. Disconnect by carefully prisingopen the plastic clip.Remove the ten spring clips, three circlips andthe two screws that secure the halves of theheater casrng together. Ensure all fixings andfoam gaskets are removed.Remove the pad from around the two coolanthose connections.Position the flap (A) as shown, prise and slideits lower edge through the gap betweenmotor housing and outer case. Whileseparating each half of the heater casing.RR2827ML7. Note for reassembly the location of the air flappivots.8. Slide out the separate panel.9. Remove the heater core complete with thesponge packing.Refit10.11.Fit the heater core into the left half of thecasing. Slide in the separate panel (8) upto thecoolant hose connections.Mark a white spot on the end of each air flappivot to be reassembled into the heatercasing.12.13.14.15.16.17.18.19.20.21.22.Offer the heater casing halves together. Ensurethe flap (A) is positioned to reverse instruction6.Point the remaining air flap pivots in thedirection of their location.Locate and slot into the left casing the heatercontrol panel assembly. Examine closely toensure that both fixings engage and slide intotheir housing.Slowly and firmly push the casing halvestogether checking that all components arealigning. Any solid resistance felt suggests acomponent is not locating correctly. Rectifyand continue until the casing halves aretogether.Refit all of the fixings that hold the heatercasing halves together.Connect the rod to the vent control lever toits marked position.Check all controls operate and air flaps sealagainst the heater casing.Renew the pad around the two coolant hoseconnections.Refit the left duct to footwell outlet.Renew the foam gaskets.Refit the heater assembly.8 ADDITION: SEPT. 89 I REVISED: MARCH 90


‘Iyo;f; 1987AIR CONDITIONINGAIR CONDITIONING-A.R.A. SYSTEMDescriptionThe A.R.A. air conditioning system comprises fourmajor units:1.2.3.4.An engine-mounted compressor.A condenser mounted in front of the radiator.A receiver/drier unit located in the enginecompartment.An evaporator unitdashboard.mounted behind theThe four units are interconnected by hoses carryingrefrigerant, and the evaporator is linked into thevehicle ventilation system.WARNING: Under no circumstances shouldrefrigerant hoses be disconnected without firstdischarging the system‘,RefrigerationcvcleThe function of the refrigeration circuit is to coolthe evaporator.1. CompressorThe compressor draws vaporized refrigerant fromthe evaporator. It is compressed, and thus heated,and passed on to the condenser as a hot, highpressure vapour.2. CondenserThe condenser is mounted directly in front of thevehicle radiator. It consists of a refrigerant coilmounted in a series of thin cooling fins to providethe maximum heat transfer in a minimum amount ofspace. Airflow across condenser is induced byvehicle movement and is assisted by two electriccondenser fans. The refrigerant enters the inlet atthe top of the condenser as a heat laden highpressure vapour.As this vapour passes down through the condensercoil=, lleai will ioilou 11s natura l tenoency ani flopfrom the hot refrigerant vapour into the cooler airflowing across the condenser coils and fins.When the refrigerant vapour reaches thetemperature and pressure that will induce a changeof state, a large quantity of latent heat will betransferred to the outside air. The refrigerant willchange from a high pressure HOT VAPOUR to ahigh pressure WARM LIQUID.3. Receiver drierThis unit filters, removes moisture, and acts as areservoir for the liquid. To prevent icing inside thesystem, extreme precautions are taken duringservicing to exclude moisture. The receiver driershould be considered as a second stage insuranceto prevent the serious consequences of iceobstructing the flow.NOTE: A sight glass provided in the unit topenables a visual check to be made of thehigh pressure liquid flow...:. . ,:_‘,.;REVISED: MAY 89 1


AIR CONDITIONINGRANGElg8’ ROVER‘.4. Expansion valve and evaporatorHigh pressure liquid refrigerant is delivered to theexpansion valve. A severe pressure drop occursacross the valve and as the refrigerant enters theevaporator space at a temperature of approximately-6”C(27”F) it boils and vaporizes. As this change ofstate occurs, a large amount of latent heat isabsorbed. The evaporator is therefore cooled andas a result heat is extracted from the air flowingacross the evaporator. The air flow is controlled bytwo evaporator fans regulated by the air conditionerfan control.Second cycleLow pressure vaporized refrigerant is drawn fromthe evaporator by the compressor and a secondcycle commences.GENERAL SERVICE INFORMATIONlntrnductionBefore any component of the air conditioningsystem is removed, the system must be discharged.When the component is replaced, the system mustbe evacuated to remove all traces of old refrigerantand moisture. The system must then be rechargedwith new refrigerant.Any service operation that requires the loosening ofa refrigerant line connection should be performedonly by qualified service personnel. Refrigerantand/or oil will escape whenever a hose isdisconnected.All work involving the handling of refrigerantrequires special equipment, a knowledge of itsproper use and attention to safety measures.Servicing equipmentThe following equipment is required for full i :servicing of the air conditioning system.Charging stationLeak detectorSafety gogglesRefrigerant charging line sealsThermometer + 20°C to -60°C (+ 68°F to -76°F)Compressor dipstickSERVICING MATERIALSRefrigerant: Refrigerant 12, which includes Freon 12or Arcton 12.CAUTION: Methychloride refrigerants must notbe used.“I\sNominal charge weight:1.19 kg (42 oz).Compressor oil: See RecommendedLubricants.PRECAUTIONS IN HANDLING REFRIGERANTRefrigerant 12 is transparent and colourless in boththe gaseous and liquid state. It has a boiling pointof -29.8% (-21.7”F) at atmospheric pressure and atall normal pressures and temperatures it becomes avapour. The vapour is heavier than air,non-flammable, and non-explosive. It isnon-poisonous except when in contact with anopen flame, and non-corrosive until it comes incontact with water.FIRST AID: If refrigerant should contact the eyes .. ..\,or skin, splash the eyes or affected area with:,, :;cold water for several minutes. Do not rub. Assoon as possible thereafter, obtain treatmentfrom a doctor or eye specialist.., ,. . ..I....::The following precautions in handling Refrigerant 12should be observed at all times.ii:.$REVISED: MAY 891, ,’ ..:. 1.: .,.:,


R”;$ 1987AIR CONDITIONING,,‘.DO NOT:(d) All replacement components and flexible end- Leave refrigerant container open to connections must be sealed, and only openedatmosphere.- Carry refrigerant container inside a vehicle.- Subject refrigerant containers to hightemperature.- Weld or steam clean near an air conditioningsystem.- Expose eyes to liquid refrigerant, ALWAYSwear goggles.- Discharge refrigerant vapour into an area withan exposed flame or into an engine intake.Heavy concentrations of refrigerant in contactwith naked flame produce a toxic gas,phosgene.- Allow liquid refrigerant to contact bright metal,it will tarnish metal and chrome surfaces, andcombined with moisture can seriously corrodeall metal surfaces.PRECAUTIONS IN HANDLING REFRIGERANTLINESimmediately prior to making the connection.te) Ensure the components are at roomtemperature before uncapping, to preventcondensation of moisture from the air thatenters.tf) Components must not remain uncapped forlonger than fifteen minutes. In the event ofdelay, the caps must be fitted.(gi Receiver/driers must never be left uncapped asthey contain Silica Gel crystals which willabsorb moisture from the atmosphere. Areceiver/ drier left uncapped must not beused, fit a new unit.(h) The compressor shaft must not be rotateduntil the svstem is entirely assembled andcontains a charge of refrigerant.:.WARNING: Always wear satety goggles whenopening refrigerant connections.(a) When disconnecting any hose or flexibleconnection the system must be discharged ofall pressure. Proceed cautiously, regardless ofgauge readings. Open connections slowly,keeping hands and face well clear, so that noinjury occurs if there is liquid in the line. Ifpressure is noticed, allow it to bleed offslowly.(b) Lines, flexible end connections andcomponents must be capped immediately theyare opened to prevent the entrance ofmoisture and dirt.(c) Any dirt or grease on fittings must be wipedoff with a clean alcohol dampened cloth. Donot use chlorinated solvents such astrichloroethylene. If dirt, grease or moisturecannot be removed from inside the hoses,they must be replaced with new hoses.ti, A new compressor contains an Initial charge of135 ml (4.6 fluid oz) of oil when received, partof which is distributed throughout the systemwhen it has been run. The compressorcontains a holding charge of gas whenreceived which should be retained until thehoses are connected.(k) The receiver/drier should be the last ..-I :.:v;component connected to the system to ‘.ensure optimum dehydration and maximummoisture protection of the system.(I) All precautions must be taken to preventdamage to fittings and connections. Slightdamage could cause a leak with the highpressures used in the system.tm) Always use two wrenches of the correct size,one on each fitting when releasing andtightening refrigeration unions.,;. :,’.’ ,.: ,,.I:.,, ‘.‘. ,’REVISED: JULY 88


AIR CONDITIONING(n) Joints and ‘0’ rings should be coated withrefrigeration oil to aid correct seating. Fittingswhich are not lubricated with refrigerant oil arealmost certain to leak.(0) All lines must be free of kinks. The efficiencyof the system is reduced by a single kink orrestriction.EvaporatorRANGEls8’ ROVERExamine the refrigeration connections at the unit. Ifthe system should develop a fault, or if erraticoperation is noticed, refer to the fault diagnosischart.SERVICE VALVES.(p) Flexible hoses should not be bent to a radiusless than ten times the diameter of the hoses.(q) Flexible connections should not be within50mm (2 In) or the exhaust manifold.(r) Completed assemblies must be checked forrefrigeration lines touching metal panels. Anydirect contact of lines and panels transmitsnoise and must be eliminated.PERIODIC MAINTENANCERoutine servicing apart from visual checks is notnecessary. The vrsuai inspections are as tollows:CondenserWith a garden hose or air line, clean the fins of thecondenser to remove flies, leave!, etc. Check thehose connection for signs of oil leakage.CompressorCheck hose connections for signs of oil leakage.Check flexible hoses for swelling. Examine thecompressor belt for tightness and condition.Checking the compressor oil level and topping-upis only necessary after charging the system or in theevent of a malfunction of the system.Receiver/DrierExamine the sight glass for bubbles with the systemoperating. Check connections for leakage.These are secured to the head of the compressor,and the suction and discharge flexible endconnections are secured to them by unions.The service valves are identitied as suction or lowpressure, and discharge or high pressure. Whilstthey are identical in operation they are notinterchangeable, as the connections are of differentsizes.The valve with the larger connections fits thesuction side. As the name suggests, these valves arefor service purposes, providrng connections toexternal pressurelvacuum pauger: for test purposes.In combination with charging and testingequipment they are used to charge the system withrefrigerant.There are two types of service valves in operation:Stem’ and Schrader’.Stem typeStem type service valves allow for the isolation ofthe compressor from other parts of the system.When these valves are used in conjunction with theliquid line quick-disconnect fittings, the three majorassemblies of the system can be removed from thevehicle with a minimal loss of refrigerant. Inaddition, it is possible to remove major assembliesfor repair of components which are not part of therefrigeration system, or provide access to parts ofthe vehicle which are obstructed by the airconditioning system, without fully discharging thesystem.‘..4 . REVISED: JULY 88...‘..


yo;;; 1987AIR CONDITIONINGNOTE: A thorough understanding of the stemtype service valve is necessary beforeundertaking servicing or repair involving the airconditioning system.RR1735MST1387MStem type service valve1. Service port.2 L’aivp stem3. Compressor port.4. Valve seat.5. Hose connector.B. MID (Test) POSITION-After the service gaugemanifold has been installed (the valve stem isin the on position), turn the valve stem therequired number of turns clockwise. This willput the valve stem seat midway in the servicevalve and allow full system operation whilepermitting refrigerant pressure to reach thegauges.’ :NOTE: A special wrench should be used toadjust the valve to prevent damage to thestem.The stem type service valve has three positions, theoperation of which is explained as follows:RR1736M;: :+::C. OFF: FULLY CLOCKWISE-With the servicevalve stem turned fully clockwise, the valve willblock passage of refrigerant flow through thesystem. As illustrated, the refrigerant flow to orfrom the compressor (depending on whetherit is high side or low side) is blocked.RR1734MWARNING: NEVER operate the air conditioningsystem with the service valves in the OFFPOSITION, it will cause severe damage to thecompressor.A. ON: FULLY COUNTER-CLOCkWISE- Normaloperating position, and the position which isused for connecting and disconnecting themanifold gauge set, is the ‘on’ position. Thestem is turned full)* counter-clockwise. Thisseals the service gauge port from receiving anyrefrigerant flow.REVISED: JULY 88 5 .’,‘. :..:.


.AIR CONDITIONING1987 RANGEROVER..,Schrader type B. OFF: FULLY CLOCKWISE- With the servicevalve stem turned fully clockwise, the valve willblock passage of refrigerant flow through thesystem. The refrigerant flow to or from thecompressor (depending on whether it is highside or low.side) is blocked.WARNING: NEVER operate the air conditioningsystem with the service valves in the OFFPOSITION, it will cause severe damage to thecompressor.Service valve caps must be replaced when serviceoperations are completed. Failure to replace capscould result in refrigerant loss and system failure.Schrader service valve1. Valve stem.2. Hose connection.3. Service valve.4. Schrader valve core.5. Compressor port..NOTE: A special wrench should be used toadjust the valve to prevent damage to thestem.The Schrader type service valve h‘as two positions,the operation of which is explained as follows:A. ON: FULLY COUNTER-CLOCKWISE- Normaloperating position, and the position which isused for connecting and disconnecting themanifold gauge set, is the ‘on’ position. Thestem is turned fully counter-clockwise. Thisseals the service gauge port from receiving anyrefrigerant flow.,: ‘.‘.:..:i.6 REVISED: JULY 88


yot$ 1987AIR CONDITIONING r82- lELECTRICAL SUPPLY SWITCHES AND FUSESThe electrical components of the air conditioningsystem draw current from three separate relaysmounted in the engine compartment closure panel.The air conditioning system is mastered from thestarter relay and is switched OFF during enginecranking.Each component in turn is energised and controlledby a series of relays and switches as indicated b)the circuit diagram.Both condenser fans operate together when the airconditioning circuit is switched ON, and when theignition is switched ON and the coolanttemperature is high, this is sensed by the enginewater temperature sensor.The three blade type fuses are located in the fusebox mounted on the lower fascia panel. They arenumbered Al to A3. It is essential to use a fuse ofthe same value when fitting a replacement. SeeElecrncal Section 86 tar relav and fuse detailsContinuedREVISED: JUNE 87


4 RANGE82 AIR CONDITIONING lg8’ ROVERIABHEATER AND AIR CONDITIONING- circuit diagram1. Heater unit.2. Resistors.3. Fan speed switch4. Air conditioninglre-circulating/fresh air-switch.5. Air conditioning/heater relay.6. Cable connection to ECU.7. Fuse 8-main fuse panel.8. Pick up point main cable connection.9. Fan relay.10. Ground-via main cable.I I. Compressor clutch relay.12. Thermostat.13. Fuse Al-auxiliary fuse panel.14. Fuse AZ-auxiliary fuse panel.15. Fuse 13-main fuse panel.16. Fuse A3-auxiliary fuse panel.17. Air conditioning motor - dashboard unit.18. Heater motor.I 9. Heater recirculating solenoid.20. Condenser fan motors.21. High pressure switch.22. Engine water temperature sensor.23. Compressor clutch..- ‘\Cable colour codeB Black G Green P PurpleU Blue s Grey R RedN Brown 0 Orange W WhiteY Yellow1 LightThe last letter of a colour code denotes the tracer.:8 . REVISED: JUNE 87‘,.:: ;:


PO;;; 1987nAIR CONDITIONING 82AIR CONDITIONING ELECTRICALMECHANICALFAULT DIAGNOSISFAULT CAUSE REMEDY//1. Incorrect voltage. I. Check voltage.2. Open or defective fuse or relay. 2. Check and replace asnecessary.3. Loose wire connection including 3. Check system wires: tightenk0T0~ground.all connections.NOPERATIVE 4. Switch open or defective.)R SLOW 5. Tight, worn, or burnt motor“5: ;$g r;:z:KJNNINGbearings.( 6. Open rotor windings.I 7. Worn motor brushes.;: ;$:: :“,:“o::8 Shaft binding-blade misaligned. 8. Check alignment. Repairor replace as necessary.9. Defective resistors. 9. Rectify or replace.1. Incorrect voltage. 1.. Check voltage.2. Open or defective fuse or rela!*. 2. Check and replace asInecessary.i 3 Defective thermostat control or i 3 Replace thermostat or1. pressure switch. pressure switch.ZLUTCH 4. Shorted or open field coil. 4. Replace coil.NOPERATIVE 5. Bearing seized (clutch will not 5. Replace bearing.disengage).6. Refrigeration circuit problem 6. Check and rectify.causing heavy load andexcessive drive torque.., :L.ZLUTCHrlOlSY1. Incorrect alignment.2. Loose belt.3. Compressor not mountedsecurely.4. Bearing in clutch-pulleyassembly not pressed in.5. Low voltage to clutch.6. Clutch will not spin freely.7. Oil on clutch face.8. Slipping clutch.9. Overloaded or lockedcompressor.10. Icing.I. Check alignment; repairas necessary.2. Adjust to proper tension.3. Repair as necessary.4. Remove clutch and replacebearing.5. Check connections andvoltage.6. Refer to 85 above.7. Check compressor sealsfor leaks.8. Refer to C5 above.9. Repair or replacecompressor.10. Check for suction linefrosting.Replace expansion valve ifnecessav.Replace receiver/drier ifnecessan/.D. 1. Motor and/or blades improperlyCONDENSERmounted.AND/OR 2. Foreign matter build-up onEVAPORATORblades.VIBRATION 3. Excessive wear of motor bearings.1. Check mountings, adjust asnecessary.2. Clean blades with a suitablenon-inflammable cleaner.3. Replace motor...:_:.:::.C Y,., ‘, ., 1.’‘. : ;REVISED: JULY 88 9.(.


AIR CONDITIONINGRANGE‘I’*’ ROVERRefrigeration system fault diagnosisFor any refrigeration system to function properly allcomponents must be in good working order. Theunit cooling cycle and the relationship between airdischarge temperature and ambient temperatureand the pressures at the compressor can help todetermine proper operation of the system.The length of any cooling cycle is determined bysuch factors as ambient temperature and humidity,thermostat setting, compressor speed and airleakage into the cooled area, etc. With thesefactors constant, any sudden increase in the lengthof the cooling cycle would be indicative ofabnormal operation of the air conditioner.The low and high side pressures at the compressorwill vary with changing ambient temperature,humidity, in-car temperature and altitude.The following items should be checked beforeoperating the system:1. Compressor drive belt tension.2. Compressor magnetic clutch operation.3. Condenser fan operation.4. Condenser fins, dirt will cause poor coolingand higher operating temperatures.The following conditions should be checked afteroperating the system for several minutes:1. All high pressure lines and components shouldbe hot to the touch.2. All low pressure lines should be cool to thetouch.3. inlet and outlel temperatures at thereceiveridrier should be at the sametemperature (warm). Any very noticeabletemperature difference indicates a blockedreceiver/drier.4. Heavy frost on the inlet to the expansion valvemay indicate a defective valve or moisture inthe system.5. With ambient humidity between 30% and60%, compressor pressures and evaporator airdischarge temperature should fall within thegeneral lrmits grven In the table below..-. ,,1.:.Type ofWeatherEvaporatorAir Temp “F(“Cl.low SidePressure p.s.i.(bar)High SidePressure p.s.i.(bar)Cool day70-80°F(21-27°C)35-45°F 15-20 160-200(1.7-7.2”(I) (1.1-1.4) (11.2-14)Warm day80-90°Ff27-32°C)40.50°F 20-25 1 go-240(4.4-l 0°C) (1.4-1.8) (13.4-16.9)Hot dayOver 90°F 45-60°F 25-30 220-270(Over 32°C) (7.2-15.6X) (1.8-2.1) (15.5-19)NOTE:1. Low and high side pressures are guides not specific limits.2. Evap. air temperatures will be lower on dry days, higher on humid days.REVISED: IULY 88


it;;,: 1987AIR CONDITIONINGFAULT CAUSE REMEDY4.’;. :2.:A.HIGH HEADPRESSURE1, Overcharge of refrigerant.2. Air in system.3. Condenser air passage cloggedwith dirt or other toreign1. Purge with bleed hose untilbubbles start to appear insight glass; then, addsufficient refrigerant gasto clear sight glass.2. Slowly blow charge to shopexhaust system. Install newdrier; evacuate and chargesystem./ 3. Clean condenser of debris.matter.4. Condenser fan motor defective. 4. Replace motor.III. Undercharge of refrigerant; i I. Evacuate and recharge theB. evident by bubbles in sight system.LOW HEAD glass while system is operating. Check for leakage.PRESSURE ! 2. Split compressor gasket or 2. Replace gasket and/or reedleaking valves. valve; Install new drier,I evacuate and charpe thesystem.3. Defective compressor. 3. Repair or replacecompressor.,:.C.HIGHSUCTIONPRESSURE1. Loose compressor belt.2. Refrigerant flooding throughevaporator into suction line;evident by ice on suction lineand suction service valve.3. Expansion valve stuck open.4. Compressor suction valvestrainer restricted.5. Leaking compressor valves,valve gaskets and/or servicevalves.6. Receiver/drier stopped; evidentby temperature differencebetween input and output lines.1. Adjust belt tension.2. Check thermobulb. Bulbshould be securely clampedto clean horizontal sectionof copper suction pipe.3. Replace expansion valve.4. Remove and clean or replacestrainer.5. Replace valves and/orgaskets. Install new drierevacuate and charge thesystem.6. Install new drier, evacuateand charge the system.,’,/’ :D.LOWSUCTIONI. Expansion valve thermobulb notoperating.2. Expansion valve sticking closed.3. Moisture freezing in expansionvalve orifice. Valve outlettube will frost while inlet hosetube will have little or nofrost. System operatesperiodically.4. Dust, paper scraps, or otherdebris restricting evaporatorblower grille5. Defective evaporator blowermotor, wiring, or blowerswitch.I. Warm thermobulb with hand.Suction should rise rapidlyto 20 lb or more. If notreplace expansion valve.2. Check inlet side screen.Clean if clogged. ReferTo C-2 and C-3.3. Install new drier, evacuateand charge the system.4. Clean grilles as required.5. Refer to Fault DiagnosisChart for blower motor.. . ..


AIR CONDITIONINGRANGEls8’ ROVERFAULT CAUSE REMEDYJ.JOISYZXPANSIONrlALVEsteadyiissing)1. Low refrigerant charge; 1. Leak test. Repair orevident by bubbles in sightreplace components asglass.required.:. I. Expansion valve not operatingINSUFFICIENT properly.COOLING 2. LOW refrigerant charge-evidentby bubbles in sight glass.3. Compressor not pumping.1. Refer to C-2, C-3, D-land E.2. Refer to B-l and E.3. Refer to B-2 and B-3c.COMPRESSORBELTSLIPPING1. Belt tension.2. Excessive head pressure.3. Incorrect alignment of pulleysor worn belt not ridingproperly.4. Nicked or broken pulley.5. Seized compressor.1. Adjust belt tension.2. Refer to A-l throughA-4 and C-6.3. Repair as needed.4. Replace as needed.5. Replace compressor.H.ENGINENOISEAND/ORVIBRATIONI. Loose or-missing mounting bolts.2. Broken mounting bracket.3. Loose flywheel or clutchretaining bolt.4. Rough idler pulley bearing.5. Bent, loose, or improperlymounted engine drive pulley.6. Defective compressor bearing.7. Insecure mountings ofaccessories; generator, powersteering, air filter, etc.8. Excessive head pressure.9. Incorrect compressor oil level.1. Repair as necessary.2. Replace bracket.3. Repair as necessary.4. Replace bearing.5. Repair as necessary.6. Replace bearing.7. Repair as necessary.8. Refer to A-l, A-2, A-3A-4 and C-6.9. Refer to compressor OilLevel Check.12 .


AIR CONDITIONINGCHARGING AND TESTING EQUIPMENTAIR CONDITIONING SYSTEMThis is standard equipment for the servicing ofautomotive air conditioning systems, and is used forall testing, trouble shooting, evacuating andcharging operations.Various designs of charging and testing equipmentare available depending upon the manufacturerchosen by the user. As slight variations do occur itis recommended that the operator adheres to theappropriate manufacturers’ instructions for theequipment in use.WARNING: The air conditioning system ischarged with a high pressure, potentially toxicrefrigerant. Repairs or servicing MUST only becarried out by an operator familiar with both thevehicle system and the charging and testingequipment.All operations must be carried out in awell-ventilated area away from. open flame andheat sources.Alwavs wear safetv goggles when openingreirigerant connections.Connecting1. Check that both service valves are fully open(turned counter-clockwise).2. Wearing safety goggles remove the dust capsfrom the gauge connections on the serviceports.3. Coat the threads and flares with compressoroil.4. Connect the charging and testing equipmentRemovingreferring to the equipment manufacturer’sinstructions.5. If the engine has been operated it must bestopped prior to disconnecting theequipment.6. Close both the service ports by turning fullycounter-clockwise.7. Disconnect the charging lines from the serviceports.8. Refit the dust caps to the compressor valvestems and service ports, and to the charginglines.Discharging the systemNOTE: The air conditioning refrigeration systemcontains ‘Refrigerant 12’ under pressure, andbefore any component is disconnected orremoved, the system must be discharged of allpressure.Refrigerant 12 evaporates so rapidly at normalatmospheric pressures and temperatures that ittends to freeze anything it contacts. Extremecare must be taken to prevent any liquidrefrigerant from contacting the skin andespecially the eyes. Should any liquid refrigerantget into the eyes, use a few drops of sterilemineral oil to wash them out and then wash theeyes with a weak solution of boric acid. Seekmedical attention immediately even though theinitial irritation has ceased after first-aidtreatment. Always wear safety goggles whenopening refrigerant connections.WARNING: Open connections slowly, keepingthe hands and face well clear, so that no injuryoccurs if there is liquid in the line. If pressure isnoticed allow it to bleed off slowly.Discharging1. Connect the manifold gauge set according tothe manufacturer’s instructions.2. Run the yellow, centre hose to anopen-topped container of approximately onelitre capacity. Attach the hose to the containerso that it will not blow out of the container.The purpose of the container is to collect anyoil carried by the refrigerant.3. Slowly open the high side valve until therefrigerant flow stops,then open the low sidevalve to remove any residual pressure.4. When discharging adjust the refrigerant flowto ensure that oil is not blown out of thecontainer.5. Measure the amount of oil discharged fromthe system. Add an equal amount of new oilto the system during the charging operation.Discard the old oil.Continued13


!,: RANGEAIR CONDITIONINGlg8’ ROVER,‘..3,’‘. ‘:‘y;, ,”:‘..,:: .’,A’EvacuateNOTE: If it is necessary to disconnect thecompressor hoses, the compressor shouldbe sealed by fully closing the relevantservice valve (turn fully clockwise). It isessential to ensure that both service valvesare open before operating the compressor.Similarly any other component of therefrigeration system should be cappedimmediately when disconnected.Whenever the system has been opened to theatmosphere it is necessav that the system beevacuated to remove all air and moisture. It is alsoan essential preliminary operation to charging thesystem with Refrigerant 12. The evacuate operationalso provides a check for leaks due to faultyconnections.Evacuating1. Discharpe the system as previouslv describedand connect the charging and testingequipment referring to the manufacturer’sinstructions.2. Slowly open the vacuum control valve. If thevacuum is applied to the system too quickly,the residual oil may be drawn out.3. In evacuating the system it is necessary tolower the pressure so that the boiling point ofwater in the system is lower than thesurrounding air temperature. At an ambienttemperature of 23.8”C (7S”F), it is necessaryto lower the system pressure to 29.5 in Hgvacuum to bring the boiling point of water to22°C (72°F). Atmospheric pressure (andvacuum gauge readings) decrease as altitudeincreases by approximately 25mm (I in) Hgper 300m (1000 ft). The following chartprovides a guide to the various gauge readingsat differing altitudes, for the same IOmm (0.4in) Hg absolute pressure.Altitude ftVacuum Readingin Hg0 29.51,000 28.52,000 27.43,000 26.44,000 25.45,000 24.56,000 23.57,000 22.68.000 21.89,000 20.910,000 20.14. The low side gauge should indicate a vacuumof 660mm (26 in) Hg within five minutes.5. If 660mm (26 in) Hg of vacuum is notachieved within five minutes, it signifies eitherthe system has a leak or the vacuum pump isdefective. Initially check the vacuum pump. ifthe pump proves to be functioning properlythen investigate for a leak in the airconditioning system.6. Continue evacuating for 30 minutes to ensurethe removal of all moisture.7. Stop the vacuum pump and allow the vacuumto hold for fifteen minutes, then check thatthere is no pressure rise (a loss of vacuum)evident on the compound gauge. Anypressure rise denotes a leak which must berectified before proceeding further. Moistureremaining in the system will continue to boiland cause loss of vacuum. Refer to theheading titled ‘Leak Detection’ later in thissection. With the system satisfactorilyevacuated, the system is ready for chargingwith refrigerant. -.Quick flushingNOTE: This operation is in addition toevacuating, and is to remove moisture fromsystems that have been open !o atmosphere fora long period, or that are known to containexcessive moisture./I. Fit a new liquid receiver/drier, as detailedunder the heading ‘Receiver/Drier’.?:,., \,,.14


PO;;; 1987AIR CONDITIONING::: ‘.. _,.,) _... ;.;‘:2. Connect the charging and testing equipmentand follow the equipment manufacturer’sinstructions for quick flushing.3. Evacuate the system.4. Allow a charge of refrigerant of between 0.25and 0.45 (0.5 to 1 lb) to enter the system.5. Allow the refrigerant introduced into thesytem to remain for ten minutes.6. Reconnect the charging and testing equipmentfollowing the equipment manufacturer’sinstructions for evacuating. Evacuate thesystem.7. Maintain the vacuum for twenty minutes. Theair conditlomng system is now ready forcharging with refrigerant.ChargeCAUTION: Do not charge liquid refrigerant intothe compressor. Liquid cannot be compressed;and if liquid refrigerant enters the compressorinlet valve, severe damage is possible; inaddition, the nil charge ma\’ be absorbed intothe reirigerant, causing damage when thecompressor is operated.Charging1. Ensure that the air conditioning system isevacuated as previously described.2. Follow the equipment manufacturer%instructions for charging the system withrefrigerant.3. Ensure that the full charge of refrigerant - LHD1.08 kg (38 oz) is drawn into the system.4. After completing the procedure check the airconditioning system is operating satisfactorilyby carrying out a pressure test, as described inthis section.Leak testThe following instructions refer to an electronictype refrigerant leak detector which is the safest,most sensitive and widely used.I. Place the vehicle in a well ventilated area butfree from draughts, as leakage from the systemcould be dissipated without detection.2. f=ollow the instructions issued by themanufacturer of the particular leak detectorbeing used. Certain detectors have visual andaudible indicators.3, Commence searching for leaks by passing thedetector probe around all joints andcomponents, particularly on the underside, asthe refrigerant gas is heavier than air.4. Insert the probe into an air outlet of theevaporator or into the evaporator drain tube.Switch the air conditioning blower on and offat intervals of ten seconds. Any leakingrefrigerant will be gathered in by the blowerand detected5. Insert the probe between the magnetic clutchand compressor to check the shaft seal forleaks.6. Check all service valve connections, valveplate, head and base plate joints and back sealplate.7. Check the condenser for leaks at the hoseconnections.8. If any leaks are found, the system must bedischarged before attempting rectification. Ifrepairs by brazing are necessary, thecomponent must be removed from the vehicleand all traces of refrigerant expelled beforeheat is applied.9. After repairs check the system for leaks andevacuate prior to charging.CAUTION: Do not overcharge the airconditioning system as this will cause excessiveheadpressure.REVISED: APR. 88 1 5 ,;::,. . .


AIR CONDITIONING~RANGElg8’ ROVER,.‘.:‘.Pressure test1. Fit the charging and test equipment aspreviously described.2. Start the engine.3. Run the engine at 1,000 to 1,200 rev/min withthe heat control set to cold (blue) zone. Cutoff the air supply to the dash vents using theleft hand lever. Move the slider levers to airconditioning ‘ON’ and fan speed to maximum.4. Note the ambient air temperature in theimmediate test area in front of the vehicle, andcheck the high pressure gauge readings-discharge side-against Table 1.5. If the pressure readings are outside the limitsquoted, refer to the fault diagnosis chart atthe beginning of this section.6. Stop the engine.7. Close both service ports (turn fullycounter-clockwise) and close all valves on thecharging and test equipment. Disconnect thecharging lines from the compressor. Refit thedust caps to the compressor valve stems, portconnections and charging lines.8. Close the hood.;,:>. P._1The pressure gauge readings will vary within therange quoted with the rate of flow of air over thecondenser, the higher readings resulting from a lowair flow. It is recommended that a fan is used foradditional air flow over the condenser if the systemis to be operated for a long time. Always use a fanif temperatures are over 26.7”C (8O”F), so that aconsistent anaivsis can be made of readings.Table 1Compound GaugeReadingsHigh PressureGauge Readings~~. 1I“C “FII16’ 60. 1,03-1,4 15-2026,7 80 l,4-I,72 20-2538 100 1,72-2,l 25-3043,5 110 2,l-2,4 30-35barp.s.i.6,9-10,3 100-l 509,6-l 3,l 140.19012,4-15,5 180.22514,8-17,2 215.250.:,: ;,;.:’. ,a. :16 REVISED: APR. 66


yo;g; 1987AIR CONDITIONING I82 1System testI. Place the vehicle in a ventilated, shaded areafree from excessive draught, with the doorsand windows open.2. Check that the surface of the condenser is notrestricted with dirt, leaves, flies, etc. Do notneglect to check the surface between thecondenser and the radiator. Clean asnecessary.3. Switch on the ignition and the air londitionerair flow control. Check that the blower isoperating efficiently at low. medium and highspeeds. Switch off the blower and the Ignition.4. Check that the evaporator condensate drainsare open and clear.5. Check the tension of the compressor drivingbelt, and adjust if necessary.6. Inspect all connections for the presence ofrefrigerant oil. If oil is evident, check for leaks,and repair as necessary.NOTE: The cnmpressor oil is soluble inRetrigerant 12 and is deposited when therefrigerant evaporates from a leak.9. With the temperature control at maximumcooling and the blower control at high speed,warm up the engine and fast idle at 1,000rev/min. Check the sight glass for bubbles orfoam. The sight glass should be generally clearafter five minutes running, occasional bubblesbeing acceptable. Continuous bubbles mayappear in a serviceable system on a cool day,or if there is insufficient air flow over thecondenser at a high ambient temperature.10. Repeat at 1,800 rev/min.11. Gradually increase the engine speed to thehigh range, and check. the sight glass atIntervals.13. Check for frosting on the service valves andevaporator fins.13. Check the high pressure hoses andconnections by hand for varying temperature.Low temperature indicates a restriction orblockage at that point.14. Switch off the air conditioning blower andstop the engineI5 I1 the air conditioning equinment is still notsatislactory. proceed with the pressure test aspreviously described in this section.7. Start the engine.8. Set the temperature control switch tomaximum cooling and switch the airconditioner blower control on and off severaltimes, checking that the magnetic clutch onthe compressor engages and releases eachtime.REVISED: APR. 88


:. /82 AIR CONDITIONING1987 RANGEROVER,...::’: ‘...‘::..I:’COMPRESSORRemove and refitRemoving1.2.3.4.5.6.7.Place the vehicle in a ventilated area awayfrom open flames and heat sources.Stop the engine and secure the hood in anopen position. Disconnect the battery negativelead.Discharge the air conditioning system.Using goggles to protect the eyes, andwearing gloves, disconnect the suction anddischarge unions from the back of thecompressor. Cap the flexible end connectionsand service valves immediately.Disconnect the lead to the compressormagnetic clutch at the connector.Loosen the idler pulley securing bolt andrelease the driving belt.Remove the two compressor mounting boltsand lift compressor clear.9. Locate the compressor in position, fit andtighten the mounting bolts.10. Fit the compressor driving belt and adjust asdescribed under ‘Compressor drive belt-adjust’.11. Connect the lead to the compressor magneticclutch at the connector.12. Refit the suction and discharge flexible endconnectors to the service valves, lubricatingthe flares and threads of the unions withcompressor oil.13. Evacuate the air conditioning system,maintaining the vacuum for ten mrnutes.14. Charge the air conditioning system.COMPRESSOR DRIVE BELTAdjust1. Loosen the idler pulley, 4mmsecuring bolt..:‘.:’ftm975Refitting8. If a new compressor is being fitted, drain theoil from the new compressor. Drain andmeasure the oil from the old compressor.Measure new oil equal to the amount drainedfrom the old compressor. Add 30 ml (I fluidoz) of new oil to this amount and refill thenewcompressor.2. Adjust the position of the idler pulley until thecorrect tension is obtained. The belt must betight with 4 to 6mm (0.19 to 0.25 in) totaldeflection when checked by hand midwaybetween the pulleys on the longest run.3. Tighten the securing bolt and recheck thetension.‘,(.,,’.“’1:.‘..;‘_’ 1.:.‘.:_’ .,:“‘.“’,., ,.1 8 REVISED: APR. 88


KAi*ucROVER lg8’ AIR CONDITIONING I82 1COMPRESSOR OIL LEVELProcedure‘.. .Sanden 510 and 709The compressor specification was changed. during1988, to a Sanden 709. The new compressor isidentified by the oil filler plug now located on theside of the compressor, and the model label.I. Open the hood.2. Fit the charging and testing equipment.3. Start the engine and turn the temperaturecontrol to maximum cooling position, and theair flow control to HIGH speed. Operate thesystem for ten minutes at engine idle speed.CheckIt is not necessar): to check the compressor oillevel as part of routine mamtenance.NOTE: The compressor oil level should bechecked whenever any components, includingthe compressor are removed and refitted, orwhen a pipe or hose has been removed andreconnected or, if a refrigerant leak is suspected.All compressors are factory charged with 135 t 15ml (4.6 L 0.5 fl 02) of oil. When the airconditloninp eauinmenr is operated some of the oilclrcurates tnroughout the system with therefrigerant, the amount varying with engine speed.When the system is switched off the oil remains inthe pipe lines and components, so the level of oilin the compressor is reduced, by approximately 30ml (I fl 02).NOTE: It is important to open the valveslowly during the following item to avoid asudden pressure reduction in thecompressor crankcase that could cause alarge amount of oil to leave thecompressor. Refer also to SERVICE VALVES.4. Reduce the engine speed to idling, andSLOWLY open the suction side valve on thetest equipment until the compound gaugereads 0 or a little below.5. Stop the engine at this point and quickly openthe suction valve and discharge valve.6 Loosen the oil filler slug and unscrew it slowlvbv five turns to oleed oft crankcase pressure.The compressor oil level must finally be checkedafter the system has been fully charged withrefrigerant and operated to obtain a refrigeratedtemperature of the car interior. This ensures thecorrect oil balance throughout the system.The compresscr is not fitted with an oil leveldipstick, and a suitable dipstick must be madelocally from 3mm (0.125 in) diameter soft wire inaccordance with the accompanying illustration. Aftershaping, mark the end of the dipstick with sixteengraduations 3mm (0.125 in) apart.RR2889MSANDEN 510 SANDEN 709Remove the oil filler plug. A l i g n t h ecounterweight to the position shown toenable the dipstick to be inserted to its fulllength.Wipe the dipstick and insert to its stopposition, ensuring the angle of the dipstick isflush with the surface of the filler orifice.RR775M3rm-n (0.125in) APARTREVISED: MARCH 90 19 ‘.(, _.’


.RANGtlg8’ ROVER15.16.17.18.19.Stop the engine.Close all valves on the charging and testingequipment.Disconnect the charging lines from thecompressor.Refit the dust caps to the compressor valvestems and gauge connections, and to thecharging lines.Close the hood.CONDENSERRemove and refitRemovingjl’9.IO.11.12.13.Withdraw the dipstick and count the numberof graduations to determine the depth of oil.Oil level - SD 510: two to four graduations.SD 709: fifteen to sixteen graduations. Add orremove oil as necessav until the mid-rangefigure is obtained. It is recommended that asyringe is used for adding or removing oil. Useonly the correct compressor oil - seeRecommended Lubricants, section 09.Lubricate a new ‘0’ ring wi!h compressor oil,fit it over the threads of the level plug withouttwisting, and install the level plug loosely.Evacuate the air from the compressor usingthe vacuum pump on the charging and testingequipment, following the equipmentmanufacturer’s instructions. Tighten the fillerplug to the correct torque, see Torque Values.Close fully the suction and discharge valves.I. Open the hood and disconnect the batterynegative lead.2. Discharge the arr conditioning system.3. Remove the front grille nanel4. Remove the radiator.5. Disconnect the two fan motor wiringconnections.CAUTION: Before carrying out instruction 6protect the eyes with safety goggles and ‘...wear protective gloves.6. Using two wrenches on each fitting, carefullydisconnect the hoses at the condenser end.Plug the exposed ends of the hoses.‘,.,”!RR777M‘i 4. Start and run the engine at 1,200 rev/min andcheck for leak at the compressor level plug.Do not overtighten to correct a leak. In theevent of a leak isolate the compressor aspreviously described in items 4 to 6, andcheck the ‘0’ ring seats for dirt, etc.7.8.Remove the vertical radiator seal from eachside.Remove four bolts securing the condenser andremove condenser complete with fan motorassemblies._’ .,120 REVISED: MARCH 90


PO;;; 1987AIR CONDITIONINGRR1659ERR1861E-9 i3 13 9Refitting9. Reverse instructions 3 to 8 above.10. Add 30 ml (I fl oz) of the correct oil to thecompressor to compensate for oil loss if anew condenser is to be fitted.11 Evacuate the air conditioning system.12. Charge the system.?Z Carr.0 out a leak test on the disturbed join!?14. Check the air conditioning operation bycarrying out a System Test.8.9.IO.Loosen the two upper bolts securing the leftand right hand hood striker support stays.Remove the bolts securing the lower ends ofthe stays and pivot both stays forward.Remove the dust caps from the fan centres.CONDENSER FANS AND MOTORSRemove and refitRemovingI. Open the hood and disconnect the batterynegative lead.2. Remove the grille panel.3. Disconnect the wiring connectors to thetransmission oil cooler.4. Loosen the fittings and detach the oil coolerhoses.5. Remove two mounting bolts from each sideand withdraw the transmission oil cooler.6. Disconnect the two fan motor wiringconnectors.7. Release the wiring securing clips.11. Remove the securing nut and washers.12. Withdraw the fan blade from the motor shaft.13. Remove the two nuts and washers securingeach motor and withdraw the fan motorassemblies from the vehicle.Refitting14. Reverse 1 to I3 above, ensuring that thewiring is correctly clipped and no fouling ofthe fan blades occurs.15. Check automatic transmission fluid level andrefill if necessary.REVISED: JULY 88 21


ll 82 AIR CONDITIONINGKANGE“*’ ROVER,RECEIVER DRIERRefitting.:.:.,,...’Remove and refitCAUTION: Immediate plugging of the receiverdrier is important. Exposed life of the unit isonly 15 minutes.Removing1. Disconnect the batter)) negative lead.2. Connect the gauge set and discharge thecomplete system..3. Protect the eyes with safety goggles and weargloves during operations 4 and 5.4. Disconnect the electrical lead at the connectorand carefully unscrew the high pressure switchfrom the receiver drier. Cover the exposedconnections immediately.9. Insert the receiver drier into the mountingbracket with the inlet and outlet connectionscorrect to the refrigerant circuit as shown.10. Connect the two hose connections fingertight. Use refrigerant compressor oil on allmating surfaces to assist leakage prevention.11. Fit the clamp bolts, washers and nuts.12. Secure the mounting bracket to the fendervalance.13. Tighten the two hose connections to thecorrect torque. see Torque Values. Use a14.15.16.IT.18.19.20.second wrench to support the hose adaptor.Carefully refit the high pressure switch to thereceiver drier. Use refrigerant compressor oilon all mating surfaces to assist leakageprevention and tighten the switch to thecorrect torque, see Torque Values. Reconnectthe electrical lead.To compensate for oil loss, add 15 ml (l/2 floz) of the correct oil to the compressor.Evacuate the complete system.Charge the complete system.Perform a leak test on any disturbed joints.Carry out a functional check.Disconnect the gauge set.\:RR781M5. Carefully disconnect the two hoseconnections. Use a second wrench to supportthe hose adaptor. Plug the exposedconnections immediately.6. Remove one bolt, nut and washers securingthe mounting bracket to the fender valance.7. Remove the clamp bolts, washers and nuts.8. Withdraw the receiver drier from the mountingbracket.:”.:.: ,’ .j :.: ‘..,. :2 2 REVISED: JULY 88;:_


AIR CONDlTlONlNG r-l 82DASHBOARD UNIT-ARA.::EVAPORATORRemove and refitExpansion valveRemove and refit 1 to 22 and 32 to 53.Hose-compressor to evaporatorRemove and refit 1 to 20 and 34 to 53.Hose-receiver drier to evaporatorRemove and refit 1 to 20 and 34 to 53.Blower unitsRemove and refit 1 to 23 and 31 to 53.Removing1.2.3.4.5.6.Open the hood and connect the gauge set.Discharge the system.Disconnect the batten! negative leadProtect the eyes with safety goggles and weargloves during instruction 5.Disconnect the evaporator hoses from thecompressor and the receiver drier. Use asecond wrench to support the hose adaptorsand plug all the exposed connectionsimmediately.Working inside the vehicle, withdraw thelower dash and remove the screws securingthe lower edge of the centre console.RR2264E7. Remove the six screws securing the loweredge of the louvre panel to the console andevaporator case.8.9.10.11.12.13.Remove the heater control panel and knobsfrom the centre console.Remove the centre console.Carefully pry out the four air vents.Remove the screws securing the evaporatorplenum and louvre panel to the dash toppanel.Carefully withdraw the thermostat sensor fromthe fins of the evaporator, and pull the sensorpipe clear of the evaporator assembly.Disconnect the electrical connectors at therear of exterior driving mirror control switchesand clock, and withdraw panel clear of thedash.ContinuedREVISED: APR. 87 23 .i’,.. :.


l-l 82 AIR CONDITIONINGRANtiElg8’ ROVER14. Remove the screws securing the lower rightmounting bracket.23. Remove the eight securing screws and detachthe blower units from the evaporator case. \24. Remove the screws securing the upperevaporator/plenum casing to the evaporatorand lower casing.25. Remove the heater seal and lift off the uppercasing.26. Remove the insulation pad and the fourscrews securing the evaporator to the lowercasing.27. Withdraw the evaporator from the casing.RR2256E15. Support the evaporator case and remove thetwo nuts securing the case and reinforcingstrip ICI the upper mounting bracket.16. Careiully withdraw the refnperant hoses andevaporator conaensate tunes through thebulkhead and remove the rear left hand airhose from the plenum.17. Disconnect the wiring to mirror controls,blower motor and clock at the three wiringconnectors.18. Remove the evaporator and plenum assemblyfrom the vehicle.Dismantling19. Remove the insulation from the evaporatorand expansion valve hose connections.20. Disconnect the hoses from the expansionvalve and evaporator. Use a second wrench tosupport the hose adaptors and plug all theexposed connection% immediately.21. Unclamp the sensor coil from the evaporatoroutlet pipe.22. Carefully unscrew the expansion valve fromthe evaporator. Plug the exposed connectionsimmediately.Assembling28. Secure the evaporator to the lower casing.29. Fit the insulation pad.30. Secure the casings together with the screwsand refit the heater seal.31. Refit and secure the blower units to theevaporator casing.32. Assemble the expansion valve to theevaporator with the inlet facing downwards.Use refrigerant compressor oil on all matinpsurfaces to assist leakage prevention. Tightenthe connection to the correct torque, seeTorque Values.33. Clamp the sensor coil to the evaporator outletpipe.34. Connect the hoses to the evaporator andexpansion valve. Use new ‘0’ rings andrefrigerant compressor oil on all matingsurfaces to assist leakage prevention.Tightenthe connections to the correct torque,seeTorque Values.35. Wrap all exposed metal at the hoseconnections with no drip tape.,24 REVISED: APR. 87


o;;; 1987AIR CONDITIONING I82 1,.;. ;.Refitting36. Place the evaporator assembly on the floor ofthe vehicle and reconnect three wiringconnectors disconnected at instruction 17.37. Feed the hoses and evaporator condensatetubes through the bulkhead. Ensure that theopenings and grommets are adequately sealedagainst ingress of dust and moisture.38. Lift the unit into the mounting position andconnect the rear left hand air hose. Fit thereinforcement strip and secure the casing tothe upper bracket with two nuts.35. Secure the lower right mounting bracket tothe vehicle.40. Position the left hand of the plenum so thatthe opening is centered over the fresh airoutlet of the heater.41. Carefully push the thermostat pipe into theevaporator fins.41. Reconnect the wiring to the exterior mirrorcontrols and clock, and refit the louvre panel.Secure the nlenum casing and louvre oanel tothe aash top panel with the fixing screws.43. Refit the centre console.44. Refit the six screws securing the louvre panelto the centre console and evaporator case.45. Secure the lower edge of the console withfour screws (two each side).46. Refit the four air vents.47. Connect the two refrigerant hoses to thecompressor and receiver drier. Use refrigerantcompressor oil on all mating surfaces to assistleakage prevention. Tighten the connectionsto the correct torque, see Torque Values.48 To compensate for oil loss, add 45 ml (I.5 flozi 01 the correct oil to the compressor.49. Evacuate the system.50. Charge the complete system.51. Perform a leak test on any accessible disturbedjoints.52. Perform a functional check.53. Disconnect the gauge set.1,;, : :;, :’RR22602REVISED: APR. 87


AIRCONDITIONING1987 KANGtROVERCOOLANT TEMPERATU