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1970-1985 Range Rover Workshop Manual

Workshop and operations manual for early Range Rover models.

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Richard Gilbert
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7K views57 pages

1970-1985 Range Rover Workshop Manual

Workshop and operations manual for early Range Rover models.

Uploaded by

Richard Gilbert
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
Repair Operation Manual 1970-1985 facluding Supplement for Manual Gearbox é Automatic Gearbox RANGE ROVER —— This manual contains supplements covering the Range Rover Five Speed manual gearbox, Transfer gearbox, Automatic gearbox and changes and additions to the Electrical equipment. Land-Rover Ltd ‘endnote some Solihull ‘A Managing Agent for Land Rover UK Limited ‘West Midlands 892 8NW PUBLICATION No. AKM 3630 (EDITION 7) England CONTENTS Preliminary 0... 0... General specification data. Engine tuning data Torque wrench settings General fitting instructions ee 07 Recommended lubricants, fuel and fluids — capacities . 08 Maintenance 10 Engine see 12 Emission and Evaporative control 1” Fuel system 19) Cooling system 26 Manifold and exhaust system - 30 Clutch 33 Gearbox — Synchromesh 37 Propeller shafts a7 Rear axle and final drive. 31 Front axle and final drive . 54 Steering 37 Front suspension 0 Rear suspension... . o Brakes 00... - 70 Wheels and tyres 14 Body 16 Paintwork ce B Heating and ventilation 80 Air conditioning . . 82 Wipers and washers . . 84 Electrical - 86 Instruments 88 Optional equipment... - 90 Service tools Supplement for Automatic gearbox at rear of manual Purchasers are advised that the specification details set out in this Manual apply to a range of vehicles and not to any particular vehicle. For the specification of any particular vehicle Purchasers should consult their Distributor or Dealer. ‘The Manufacturers reserve the right to vary their specifications with or without notice, and at such times and in such ‘manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer's policy of constant product improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer nor the Distsibutor or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof. © Rover Group Limited 1985 This book is published by Brooklands Books Limited under licence and is based upon text and illustrations protected by Copyright and first published in 1985 by Land Rover Limited and may not be reproduced, transmitted or copied by any means without the prior written permission of Rover Group Limited, o1-2 INTRODUCTION ‘The purpose of this cumulative manual is to assist skilled mechanics in the efficient repair and maintenance of Range- Rover vehicles from their inception. The procedures detailed, carried out in the sequence given and using the appropriate service tools, will enable the operations to be completed in the time stated in the Repair Operation Times, Indexing For convenience, this Manual is divided into a number of divisions. A contents page listing the tiles and reference ‘numbers of the various divisions is shown opposite. A list of the operations within each of the divisions appears in alphabetical order on the contents page preceding each of the divisions, Operation Numbering Each operation is followed by the number allocated to it in a master index. The number consists of six digits arranged in three pairs, ‘The master index of operations has been compiled for universal application to vehicles manufactured by BL Limited and therefore continuity of the numbering sequence is not maintained throughout the Manual, To assist with locating information, each division of the Manual is preceded by a contents page listing the operations in alphabetical order. Each instruction within an operation has a sequence number and, to complete the operation in the minimum time itis essential that these instructions are performed in numerical sequence commencing at 1 unless otherwise stated. Where applicable the sequence numbers identify the components in the appropriate illustration. Where performance of an operation requires the use of service tool, the tool number is quoted under the operation heading and is repeated in, or following the instruction involving its use. ‘An illustrated list of all service tools necessary to complete the operations described in the Manual is also included. References References to the left or right hand side in the Manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the water pump end of the engine is referred to as the front. Repairs and Replacements When service parts are required itis essential that only genuine Land Rover replacements are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturers’ specification. Torque wrench setting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified, must be fitted. Ifthe efficiency of a locking device is impaired during removal it must be renewed. ‘Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted loca- tion on the car conform to mandatory requirements existing in their country of origin ‘The vehicle warranty may be invalidated by the fitting of other than genuine Land Rover parts All Land Rover replacements have the full backing of the factory warranty, Land Rover and Range Rover Distributors and Dealers are obliged to supply only genuine service parts. SAFETY POISONOUS SUBSTANCES. WARNING ‘Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should as far as possible be kept away from ‘open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives. FUEL HANDLING PRECAUTIONS ‘The following information provides basic precautions which ‘must be observed if petrol (gasoline) is to be handled safely. It also outlines the other areas of risk which must not be ignored. ‘This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of your local Fire Officer. General Petrol/gasoline vapour is highly flammable and in confined spaces is also very explosive and toxic. When petrol/gasoline evaporates it produces 150 times ‘own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier ‘than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/ sasoline is potentially very dangerous. ‘Always have a fire extinguisher containing FOAM CO; GAS ‘or POWDER close at hand when handling or draining fuel, ‘or when dismantling fuel systems and in areas where fuel containers are stored. Always disconnect the vehicle battery BEFORE carrying ‘out dismantling or draining work on a fuel system. Whenever petrol/gasoline is being handled, drained or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any lamps used must be flameproof and kept clear of spillage. NO ONE SHOULD BE PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH PETROL/ GASOLINE WITHOUT FIRST HAVING HAD SPECIA- LIST TRAINING. 1-4 Fuel Tank Draining WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST IT IS STANDING OVER A PIT. Draining or extracting petrol/gasoline from vehicle fuel tank must be carried out in a well ventilated area, ‘The receptacle used to contain the petrol/gasoline must be more than adequate for the full amount of fuel to be extracted or drained, The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations. WHEN PETROL/GASOLINE HAS BEEN EXTRACTED ‘OR DRAINED FROM A FUEL TANK THE PRECAU- TIONS GOVERNING NAKED LIGHTS AND IGNITION ‘SOURCES SHOULD BE MAINTAINED. Fuel Tank Removal On vehicle where the fuel line is secured to the fuel tank outlet by a spring steel clip, itis recommended that such clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedure will avoid the possibility of residual petrol fumes in the fuel tank being ignited when the clips ae released. ‘As an added precaution fuel tanks should have a PETROL/GASOLINE VAPOUR warning label attached 0 them as soon as they are removed from the vehicle. Fuel Tank Repair Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following methods: (@) STEAMING: With the filler cap and tank unit re- moved, empty the tank. Steam the tank for at least 2 hours with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any sediment and sludge not volatised by the steam, is washed out during the steaming process () BOILING: With the filer cap and tank unit removed, ‘empty the tank. Immerse the tank completely in boiling water containing an effective alkaline degreas- ing agent or a detergent, with the water filling and also surrounding the tank for at east 2 hours. After steaming or boiling a signed and dated label to this, effect should be attached to the tank. ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL. ‘Across flats (bolt size)... AF After bottom dead centre . ‘ABDC After top dead centre ATDC Alternating current ac. Ampere amp Ampere-hour amp hr ‘Atmospheres : Atm Before bottom dead centre... 5 BBDC Before top dead centre BTDC Bottom dead centre... BDC Brake mean effective pressure |... ...... BMEP Brake horse power . ‘bhp British Standards... 2... BS Carbon monoxide... ... co Centimetre ...... em Centigrade (Celcius) c Cubic centimetre em? Cubic ineh in? Degree (angle) deg or deg or Degree (temperature) Diameter : Direct curzent Fahrenheit Feet Feet per minute Fifth : Figure (illustration) . First Fourth .. Gramme (foree) . Gramane (mass) Gallons Gallons (US). High compression High tension (electrical) Hundredweight Independent front suspension Internal diameter Inches of mercury ee Inches a Rilogfaries (lorcs) ee gr, Kilogramme (mass) 0... ke Kilogramme centimetre (torque) kgfem Kilogramme per square centimetre : Kilogramme metres (torque)... kfm Kilometres .. to ceecs km Kilometres per hour Kilovolts . : King pin inclination orreeeen Lefihand steering 2 Lite Leftchand thread Litres - Low compression Low tension Maximum Metre Microfarad. Midget edison screw : cesses MES Millimetre . i : mm Mites per galion 2.5.2... + mpg lie pes hour etal Ademco cain mioate Gna) eee ee a linus (66 tolerance) ee eee Negative (electrical). Number Ohms Ounces (force) » Ounces (mass) . Ounce inch (torque) . Outside diameter Paragraphs . . Part number Percentage . . Pints. Pints (US) Plus (tolerance) Positive (electrical) Pound (force) 7 Pounds feet (torque) . . Pounds inches (torque) Pound (mass) Pounds per square inch Radius Rate (frequency) . Ratio Reference ef. Revolution per minute . rev/min Right-hand RH Right-hand steering RHStg Second (angle) se Second (numerical order) + 2nd Single carburetter - SC Specific gravity + Pg. Square centimetres. om? ‘Square inches in? Standard. std. Standard wire gauge... sw. Synchroniser/synchromesh . .... s+ synchro. iThaied eee ere eee reper ee ard) Tapdesd cone tsp pees et TDC Twin carburetters TC United Kingdom ‘i UK Vehicle Identification Number +. VIN Volts .v Watts w SCREW THREADS ‘American Standard Taper Pipe . NPTF British Association . . BA Standard Standard Fine BSF British Standard Pipe . ~ BSP British Standard Whitworth. ~ Whit. Unified Coarse ..... 2... se ees UNC Unified Fine [Link] eee eee. UNE, General Specification Data ENGINE Type ‘Number of cylinders Bore Stroke Capacity Valve operation Main bearings ‘Number and type Material Connecting rods ‘Type Valve timing Opens Closes Duration Valve peak Valve timing (9.35:1 engine, ow lift camshaft) Opens Closes Duration Valve peak Big end bearings ‘Type and material Pistons Type Gudgeon pin Type Camshaft Drive ‘Timing chain Tappets ‘Type Lubrication System type System pressure Oil pump type Oil filter COOLING SYSTEM Type Type of pump FUEL SYSTEM Carburetter Make/type Fuel pump Make/type va Eight, two banks of four 88,90 mm (3.500 in) 71,12 mm (2.800 in) 3528 em? (215 in®) Overhead by pushrod 5 Vandervell shells Lead indium Horizontally split big end, solid small end Inlet Exhaust 30° BTDC 68° BBDC 75° ABDC 37° ATDC 285° 285° 112.5° ATDC 105.5° BTDC Inlet Exhaust 36° BTDC 74° BBDC 64° ABDC 26° ATDC 280° 280° 99° ATDC 119° BTDC Vandervell VP lead indium/aluminium tin Aluminium alloy, concave crown. Plain skirt (early 8.25:1 engines) “W slot skirt (late 8.25:1, all 8.13:1 and 9.35:1 engines) Press fit in connecting rod (Chain and sprocket from crankshaft 9,52 mm (0.375 in) pitch $4 links x 22.22 mm (0.875 in) width Hydraulic, non adjustable ‘Wet sump, pressure fed 2,1 to 2,8 kg/em? (30 to 40 Ibjin®) at 2400 rev/min Gear Fullflow, self contained cartridge Pressurized spill return system with thermostat control, pump and fan assisted Centrifugal ‘Twin Zenith, 175 CDSE Refer to engine tuning data for other details. ‘AC, mechanical (earlier models) or electrical (later models) ont General Specification Data CLUTCH Make/type Clutch plate diameter Facing material Number of damper springs Damper spring colour Clutch release bearing GEARBOX Main gearbox ‘Type Speeds ‘Synchromesh Ratios Fourth (Top) ‘Third Second First Reverse Transfer gearbox Type Ratios Gearbox suffix High Low Overall ratios (Final drive) Gearbox suffix Fourth (Top) Third Second First Reverse PROPELLER SHAFTS Type Ur sal joints REAR AXLE Type Ratio FRONT AXLE Type “Angularity of universal joint on full lock Ratio ROAD SPRING SPECIFICATION ~ 1981 (interchangeable only in sets for earlier vehicles) Borg & Beck, diaphragm type 266,5 mm (10.5 in) Raybestos WR7 or H.K. Porter 11046 6 Light grey/ereen Bal journal Single helical constant mesh 4 forward | reverse All forward speeds 1 1.505:1 2.448:1 4,069:1 3.664:1 ‘Two speed reduction on main gearbox output, Front and rear drive permanently engaged via a lockable differenti ‘K&B OC ., ” L141 11131 1.4231 0996:1 3321 332:1 3.321 332K high transfer low transfer WEB OC . ” All models 4161 3941 3971 3831 11761 6251 $931 $98: $30: 17.69:1 1017] 9.64:1 9.72:1—-B63:1—-28.78:1 1691:1 16.031 16.16:1 14.34: 47.84:1 18.23:1 1443:1 1456:1 1291:1 43.08:1 * Suffix °C’ from gearbox No, 355 94060 C ** Prefix 12C° Open type 50,8 mm (2 in) diameter 1310 type, wide angle variety on front shaft only (Gaiter fitted to stiding coupling of front shaft) Spiral bevel, fully floating shafts 354:1 Spiral bevel, enclosed universal joints 32° 3.54:1 = - ~ [___ STANDARD SUSPENSION _t SPECIFICATION. HEAVY DUTY SUSPENSION _ + SPECIFICATION RHD FRONT A‘ RHDFRONT E |__THD FRONT ight side) A deft side) B_ | LHD FRONT (ight side) E deft side) F RHD REAR c RHD REAR ¢ THD REAR Giant side) C (ettsideyD | LHD REAR (igh side) G (et side) H General Specification Data ROAD SPRING DATA ~ ALL VEHICLES +SPECIFICATION | PARTNUMBER | — COLOUR CODE RATING | FREELENGTH | [Link] cous not curtent 90875625 yellow stripe 2321S kgim | 414.29mm 7 (130 fe) (6341n) | not current 620101 yellow stipe 3035.86 kg/m | 430.53mm Bas (170 Boia) 695m) cae NRC2119 een stripe 2678.7 kgim | 409-70mm 163 (130 ton) (16.13 in) A sms blue stipe 2375.1kgim | 39116mm 718 | (133 to/m) (5.4) G NRC4234 | green & yellow stripe | 3035.86Kg/m | 411.48mm 7.00 (70 bia) (16.20 i) H NRC 4304 red & white stripe | 3035.8643(m | 450.53mm 7.00 | (70 hii) (16.95 in) Dar NRC 4305 ed & yellow stipe | 2678.7 kgim $36.4mm 165 (s0 tein) aTA8i8) B NRC4306 blue & white stipe | 2978.1 kgm | 417.57mm 155 \ ao (133 tom) (sadn) ‘SHOCK ABSORBERS (DAMPERS) ‘Type (internal valving modified 1981) LEVELLING UNIT Type STEERING Manual steering Make/type Ratio ‘Steering wheel turns, lock-to-lock. Power steering Make/type Ratio ‘Steering wheel turns, lock-to-lock Steering wheel diameter Front wheel alignment Camber angle Castor angle Swivel pin inclination HYDRAULIC DAMPERS, Type. Bore diameter BRAKES Foot brake Type Operation Front brake Type Disc diameter Hydraulic, double acting telescopic, 35mm bore (interchangeable only in sets for eatlier vehicles) Boge Hydromat, self-energising Burman/ecirculating ball, worm and nut Variable: straight ahead 18.2:1 (Non Tie Bar Type) 20.55:1 (Tie Bar Type) 4.9 early models, 5.55 later models ‘Adwest Varamatielinkage Variable: straight ahead 17.5:1 3.375 431,8 mm (17 in) 1,2 to 2,4 mm (0.046 to 0.094 in) toe out O° Check with vehicle in static unladen condition, that is, vehicle with water, oil and five gallons of fuel. Rock the vehicle up and down at the front to TP allow it to take up a static position, Telescopic, double acting non adjustable 35,47 mm (1.375 in) Dise Hydraulic, servo assisted, self adjusting ‘Outboard dises with four pistons 298,17 mm (11.75 in) General Specification Data Rear brake ‘Type Dise diameter Total pad area Total swept area Pad material ‘Transmission brake ‘Type Diameter Width Lining material WHEELS Size/type Tyres Size/type ELECTRICAL EQUIPMENT System Fuses Battery Make/type ~ basic ~ heavy duty Starter motor ‘Make/type — early models — later models Wiper motor Make/type — Windscreen — Tailgate and headlamp Horns Make/type Distributor Outboard discs with two pistons 290,0 mm (11.42 in) 317,34 om? (49.2 in*) 3199,2 em* (496 in?) Ferodo F2430, F2431 or Don 230 Mechanical, hand operated, duo-servo drum brake on rear of transfer gearbox output shaft 184,05 mim (7.25 in) 76,2 mm (3.0 in) Don Capasco 24 6.00 IK x 16 205 x 16 Radial ply (tubed), Michelin X M +S, Goodyear ‘Wingfoot’, or Firestone Town and Country 12 volt, negative earth 35 amp, blow rating Chloride (6TWL9Z1) 291 Chloride (6TWZ13R) 369 (or Lucas (OCP 13/11)389 Lucas M45, pre-engaged ‘Lucas 3M100 pre-engaged Lucas 17W, two speed, self-switching Lucas 14W single speed, selfswitching Lucas 6H or Mixo TR89 Refer to engine tuning data General Specification Data Alternator [7 Manufacture ‘Lucas Lucas ‘Lucas Lucas Type 16 ACR 18 ACR 25 ACR 133/65 | Polarity ‘Negative earth [Negative earth [Negative earth Negative earth Brush length New 12,70mm (0.5 in) 12,70mm (0.5 in) 12,70mm (0.5 in) 20mm (0.78 in) ~ Worn, minimum free protrusion from brush box: 5,00mm (0.2 in) | 8,00mm (0.3 in) 8,00mm (0.3 in) 10mm (0,39 in) ‘Brush spring pressure ~ flush with brush 198 t0 283g 255103708 255 10 3708 136 0279 g box face (7 t0 10.02) @ to 13 02) 91013 02) (to 1002) Rectifier pack output rectification | 6 diodes (live side | 6 diodes (ive side | 6 diodes (3 live side__| 6 diodes (3 live side and 3 earth side) = field winding supply and 3 earth side) and 3 earth side) and 3 earth side) retention 3 diodes 3 dogs 3 diodes aShClUe— Space cometed| 3 pn dea comected eee ae 2 [2 2 k “Taimum seed | 1Eg00revnin | 15,00revimin | 15,000sviin——| 15,000 ceva “ianaced mhemeiune, | Mie-lse wietsy mse ange ence mote 4stsnonme | a20nme Cr conv Sauce ened | Bator soned | Dualaterysemed | Dalat sod | mementos | Semmacsecemea | witmachgsemed | neces ieee toy sonal Sey emer Steyn |) euaion-ope | BR ome ore tk | CS ——_. | Cee : es = os ~ernmr pet | O00 se/nin 5600 revinin _ 7 Tonle | Stat tarot Tevet cen Seam Som Sim Sin Replacement Bulbs Tye Teadlanpe Tress No. SEE GOSS]W Glog Pe) Headlamps — France Pin SHG? SSN Gre), Sicelampe eect ree Stopfal las Enter | Lucas No. 380,12, 6/210 Reverse lamps Tamps. | LucesNo. 382, 124,21 Rea fog guar lamps Leas No, 382,120, 2 | Diesen ora Leas No, 382,120,219 Side repeater lamps | Tics No. 989, 124,60 Number plate lamps Leas No. 233, 12 4w Ite parla wis Sra No 062174, 1.3. en Hazard warning svitch amp Teas No, 281, 129,20 = Interior rot lamp festoon bulbs interior | Leas No. 254,120 60 Differential lock warming lamp tamps | Lucas No. 987,120, 2.20 Chock ilumintion Leas No. 281, 129,20 Under bonnet iumination : Wedge bse, 20, Sv apis = General Specification Data ‘Vehicle Dimensions Overall length. Overall width, Overall height Wheelbase : ‘Track: front and rear... Ground clearance: under differential 447m (176 in) + 1,78m (70 in) 1,78m (70 in) + 2,54m (100 in) + 148m (58.5 in) 190mm (7.5 in) ‘Turning circle. 11,28m (37 ft) Loading height 660mm (26 in) Maximum cargo height. 1,01m (40 in) Rear opening height 1,01m (40 in) Usable luggage capacity, rear seat folded . ‘Usable luggage capacity, rear seat in use = four door vehicles = two door vehicles. . ‘Maximum roof rack load Vehicle weights 2,00 cu.m (70 [Link]) 1,02 cu.m (36.18 [Link]) 1,17 cum (41.48 [Link]) 175 ke (165 Ib) UNLADEN WEIGHT EEC KERB WEIGHT GROSS VEHICLE WEIGHT Vehicle Bont | Rear] oe | Font | Rear Type | Axle | Axle | Tots | axle | Axle | Toit | Axe | Axle | Total Four | 9095 | _s84kg | 1793ke | _928kq | 999k | 1927Ky | 1000K@ | 1SiOKy | 2510Kg Door | 20041 | 194916 | 39531 | 20461 | 22021 | a248i | 22051 | 3329Ib | saa. Two | 893ke | 869kg | 1762k— | 912kq | 983kg | 1895Ke | 1000Kg | 1510Kg | 2510K8 Door | 19691 | 19iei | ssesib | 201i | 2167 | 417s | 22051 | 33296 | ss3ate Note: UNLADEN WEIGHT isthe minimum vehicle specification, excluding fuel and diver EEC KERB WEIGHT is the minimum vehicle speci ation, plus full fuel tank and 75 kg (165 Ib) driver. GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver, passengers, payload and equipment. This figure is liable to vary according to legal requirements in certain countries Maximum permissible towed weights On-toad | Off-road Trailers without brakes 500kg | 500Kg 1oo1b | 1100 Trailers with overrun brakes ‘| 2000k— | 100k. 7 44oot | 220015 4-wheel trailers with continuous or semi-continuous brakes ie. coupled brakes 4000kg | 1000kg 88001 | 22001 Note: It is the Owner's responsibility to ensure that all regulations with regard to towing are complied with. This applies also when towing ebroad. All relevant information should be obtained from the appropriate ‘motoring organisation, Engine Tuning Data ENGINE Type va Capacity 3528 em? (215 in?) ‘Compression ratio (depending on market and model year) ——_8.25:1,8.13:1 or 9.35:1 Firing order 1-8-4-3-6-5-7-2 ‘Cylinder numbering system front to rear ~ Left bank 1-3-5-7 — Right bank 24-68 Compression pressure (minimum) 9,5 ke/om® (135 Ibjin®) ‘Timing marks On crankshaft pulley ‘Valve clearance Not adjustable IGNITION Coil Make/type Lucas 16 C 6 with ballast resistor ENGINE TUNING ‘The following tables show the engine specification changes introduced from the inception of the Range Rover. One of the table headings is ‘Tuning Procedure’ with numbers 1 to 4 listed against each carburetter identification tag. ‘The numbers 1 to 4 indicate which of the tuning procedures listed after the table should be used in each particular case, In the case of Suffix ‘F* emission controlled engines use the tuning procedure 3 or 4 depending upon whether the carburetters are non-tamperproofed or tamperproofed type. ‘esos. caval aaa | Sel EI AMBER © IDENTIMCATION [caRguRErTER) Negpie | ruxinc DISTRIBUTOR | TIMING | RATING | AND | COMPRESSION | | SUFFIX |_| TAG [NEEDLES ADJUSTMENT | PROCEDURE | (RON) | GAP. RATIO. aes | NET 3283 200 ‘Bottom 1 ‘Rover No. 611390 | 3 Degrees La7Y 8251 SER [RR | coal a eee TE] a] |] epee a Et q NA | SEBS | TDS. 85 | 9.025in Sea |e | L arbe 635mm) | Cac eed _ 8 ra a Sore] | eee] © | gam | BDC. 0.800m) | | | inca hana] AEBS | : leeeeee ell anbe Sem | | | ‘TNE NON EMISSION ENGINES E — EMISSION CONTROLLED ENGINES Engine Tuning Data ‘TUNING PROCEDURE | (BOTTOM ADJUSTMENT) Idle Setting With engine at operating temperature (Warm Air Intake Valve Open, where fitted) the mixture change is effected by adjusting the jet assembly. Idle speed 550 to 650 rev/min. ‘TUNING PROCEDURE 2 (BOTTOM ADJUSTMENT) Idle Setting With engine at operating temperature (Warm Air Intake Valve Open) the mixture change is effected by adjusting the jet assembly. Zenith tool, Part No. B 24667, is required for this operation, Method 1. Locate the tool in the slots at the base of the jet assembly. 2. Turn in a clockwise direction to richen mixture, and anti-clockwise to weaken the mixture, Mixture settings Exhaust C.O. 3.0 to 4.5% Idle Speed 700 to 750 sev/min NOTE: On new engines idle speed will be lower for the initial running in period. Fast idle Operation of the choke from ‘ON’ to ‘OFF” should result in a fast idle speed of 1200 + SO rev/min when the choke control is approximately 12.70 mm (0.5 in) from the [Link] position. Should adjustment be required, the following procedure rust be used:— 1. Remove the L.H. carburetter from the engine 2. Put the Starter Unit Adjusting Pin into the full choke position (pin in the groove). 3. With the Starter Unit held in the full choke position, it should be just possible to insert a 0.9 mm (No. 65) drill between the top edge of the throttle plate and the throttle barrel wall. 4, To adjust the setting, release the locknut on the dome head screw fitting in the throttle lever that contacts the ‘Starter Unit Cam, adjust the serew to obtain the required setting, tighten the locknut and recheck the gap. 5. Replace the adjusting pin in the reduced choke position, 6. Refit the LH. carburetter to the engine. ‘The following components are preset and non-adjustable. a. Temperature compensator. b. Poppet valve Should these units be suspected of malfunction they must be changed. Fuel Deflector Plate ‘This must be fitted between the inlet manifold and the carburetter insulating block, with the saw teeth facing downstream of the carburetter. The plate will foul the carburetter butterfly plate if fitted between the carburetter and insulator. ‘TUNING PROCEDURE 3 (TOP ADJUSTMENT) Idle Speed and Mixture Setting Exhaust C.0. 3.0 to 4.5% at 700 to 750 rev/min, NOTE: On new engines idle speed will be lower for the running in period, Fast Idle Setting 1200 + 50 rev/min with the engine at normal operating temperature. Idle Mixture Setting Before proceeding with adjustment the engine should be at normal operating temperature (Warm Air Intake Valve Open) and the Carburetters balanced. Equipment requiced:~ CO Meter Calibrated Tachometer ‘Mixture Adjustment Tool ~ Part No. $353 (Zenith B 20379) ‘Allen’ key type or Part No. MS 80 (Zenith B 25860) slotted socket type. To meet certain new legislative requizements recent carburetters employ a raised blade instead of an ‘Allen’ Key socket for adjusting the mixture needle. This necessitates the provision of alternative tools. 0s-2 Engine Tuning Data Mixture adjustment is made by changing the metering needle position relative to the fixed jet orifice using the appropriate adjustment tool, as follows:— 1. Remove the piston damper. 2. Insert the adjustment tool, into the piston guide rod, ensuring that the peg on the outer barrel of the tool engages {in the slot in the guide rod, this prevents the piston from rotating and consequently damaging the diaphragm. 3. Push down the adjustment tool until it engages in the metering needle housing. 4. Turn the tool in a clockwise direction to richen the mixture, and anti-clockwise to weaken the mixture. NOTE: The adjustment tool should be removed from the guide rod after every adjustment, to allow the engine to stabilise following the piston being depressed during adjustment. Run the engine for a few seconds at 2000 rev/min to aid stabilisation. S. Refit the piston damper. 6. Slight adjustment to idle speed and/or carburetter balance may be required after refitting the piston damper, there- fore run the engine at approximately 2000 rev/min for 20 seconds, make idle and balance adjustments, if necessary, before taking final C.O. reading. NOTE: The metering needle will normally be set with the shoulder of the needle flush with the face of the piston; this is termed the datum position, If difficulty is experienced with carburation the needle should be set to this datum for investigation. When using the adjustment tool, a positive stop will be felt when the needle reaches the fully rich position. In the anti-clockwise or weakening direction there is no stop and itis possible to disengage the needle from the adjustment screw if more than two turns are made from the datum position, Should disengagement occur, it can be rectified by applying light pressure in an upwards direction, to the shoulder of the needle at the piston face, while turning the adjustment tool in a clockwise direction. Poppet Valve and Temperature Compensator ‘These assemblies are preset and non-adjustable. If a malfunction occurs on either component, the carburetter must be replaced. Fast Idle Setting Operation of the choke from ‘ON’ to “OFF” should result in fast idle speed of 1200 + 50 rev/min when the choke control is approximately 12.70 mm (0.$ in) from the fully-in position ‘Should adjustment be required, proceed as follows:— 1. Slacken the choke cable clamping screw at the carburetter. 2. Pull the choke control knob out to a distance of approximately 12,70 mm (0.5 in) and turn to lock-in position 3. Tur the fast idle cam, allowing the choke cable to slide through the trunnion until the punched mark on the cam flank aligns with the centre of the domed fast idle screw and tighten the clamping screw. 4, With the cam held in this position, adjust the fast idle screw to obtain a fast idle speed of 1200 + SO rev/min and retighten the locknut. 5. Push the choke control knob fully home and check that normal idle speed is regained. ADJUSTMENT PROCEDURE 4 (TOP ADJUSTMENT TAMPERPROOFED) To comply with ECE exhaust emission regulations, all carburetters must be tamperproofed on the idle adjustment screws. ‘Therefore, after mixture and speed tests have been finalised, the carburetter must be tamperproofed by fitting a cap to the nylon shroud on the idle adjusting screw. Cap = Part No. ERC 3429 Cap fitting toot = Part No. ERC 3786 ‘Should, for any reason, the cap require removal, this can be effected by piercing the cap with a sharp pointed tool and prising out. ‘The following tools will be required to adjust idle speed, mixture and tamperproof carburetter:— Idle speed adjustment tool = Part No. MS 86 (Zenith B25243) “Idle Mixture adjustment tool _Part No. $353 (Zenith B20374) ‘Allen’ key type or Part No. MS 80 (Zenith B25860) slotted socket type ‘Tamperproof Cap fitting tool ~ Part No, ERC 3786 Acnumerical code exists for the tamperproofed cap and must be adhered to: Cap fitted by Land Rover Service Departments: Part No. ERC 3429 “To meet certain new legislative requirements, recent carburetters employ a raised blade instead of an ‘Allen’ key socket for adjusting the mixture needle. This necessitates the provision of alternative tools. 05-3 Engine Tuning Data The carburetters will be preset by the manufacturers to engineering requirements and should not normally require adjustment, However, should adjustment be required, the following method must be used. Idle Setting — with engine to normal operating temperatures Exhaust C.0. 3.0 to 4.5% (9.35:1 engine 2.0 to 3.5%) Idle Speed 700 to 750 rev/min, Fast Idle Setting: 1200 #50 rev/min NOTE: On new engines idle speed will be lower for the initial running in period. Tale Mixture Adjustment Engine should be at normal operating temperature (Warm Air Intake Valve Open). Mixture adjustment is effected by changing the metering needle position, relative to the fixed jet orifice, using the appropriate adjustment tool, 1. Remove the piston damper. 2. Insert the adjustment tool into the piston guide rod, ensuring the peg on the outer barrel of the tool locates in the slot in the guide rod, this prevents the piston twisting with consequent damage to the diaphragm, 3. Push down the adjustment tool until it engages in the metering needle housing. 4. Turn the tool in a clockwise direction to rich the mixture and anti-clockwise to weaken the mixture, NOTE: The adjustment tool should be removed from the guide rod after every adjustment, to allow the engine to stabilise, following the piston being depressed during adjustment. Run the engine for a few seconds at 2000 rev/min to aid stabilisation, 5. Refit the piston damper. 6. Slight adjustment to idle speed and/or carburetter balance may be required after refitting the piston damper, there- fore run engine at approximately 2000 rev/min for 20 seconds, make idle and balance adjustments, if necessary before taking final C.O. reading, NOTE: The metering needle will normally be set with the shoulder of the needle flush with the face of the piston, this is termed datum position. If difficulty is experienced with carburation the needle should be set to this datum for investigation. ‘When using the adjustment tool, a positive stop will be felt when the needle reaches the full rich position. In the anti-clockwise direction there is no stop and it is possible to disengage the needle from the adjusting screw, if more than two turns are made from the datum position, Should disengagement occur, it can be rectified by applying light pressure, in an upwards direction, to the shoulder of the needle at the piston face, while turning in a clockwise direction. Idle Speed Adjustment ‘To adjust the idle speed, the following procedure must be followed :— ‘Slacken the small bolts on the throttle levers to allow independent adjustment. Using tool, Part No, MS86 (Zenith B25243) slacken the locknuts on the idle speed adjustment screws. Adjust the screws to obtain correct idle speed and just nip the locknuts. Check C.O. reading, check carburetter balance, correct if necessary. When 3 and 4 are satisfactory, tighten the locknuts and reset the throttle Recheck the idle settings, Fit cap, Part No. ERC 3428, using tool, Part No. ERC 3786 to the nylon shroud surrounding the adjusting screw. Fast Ldle Setting Operation of the choke from ‘ON’ to “OFF” should result in a fast idle speed of 1200 + $0 rev/min when the choke control is approximately 12.70 mm (0.5 in) from the fully-in position. Should adjustment be required, proceed as follows:— 1, Slacken the choke cable clamping screw at the carburetter. Pull the choke control knob out and push in toa distance of approximately 12.70 mm (0.5 in) and lock in position. 3. Tum the starter cam, allowing the choke cable to sistide through the trunnion until the punched mark on the cam flank aligns with the centre of the domed screw on the starter/throttle lever and tighten the clamping screw. 4, With the cam held in this position, adjust the fast idle screws to obtain a speed of 1200 + $0 rev/min and retighten the locknut, 5. Push the choke cable fully home and check that normal idle speed is regained. Engine Tuning Data ‘Vacuum Retard Switch European (Pre 1975) and all Australian Vehicles ‘Setting: The gap between the cam and switch pad to be 0:900 to 1,02 mm (0.035 to 0.040 in). Procedure:— Slacken the nuts retaining the switch to the bracket. Depress the switch pad fully ‘Adjust the switch to correct the gap between the cam and the switch pad. ‘Tighten the switch retaining nuts Open the throttle fully, and close slowly to ensure the throttle is not propped open by the cam contacting the top edge of the switch pad. If the cam is propped, this will probably be due to misalignment of the switch pad to cam, ‘Vacuum Capsule Test To ensure that the vacuum capsule is functioning correctly, it is important that the following procedure is carried out: Remove the vacuum retard pipe from the distributor (this will increase the idle speed). If the vacuum capsule is functioning correctly, an advance to between 6 to 14 degrees B.T.D.C. should be noted. If this advance is not achieved the distributor should be changed, DISTRIBUTOR NOTE: Different distributors have been fitted according to model year and market requirements. The information given below is for guidance only and the unit should be identified by the number stamped on the distributor body. Make/type Lucas 35D8 Rotation of rotor Clockwise Dwell angle 26° to 28° Contact breaker gap 0,36 mm to 0,40 mm (0.14 in 10 0.16 in) Condenser capacity (0.18 t0 0.25 microfarad Engine suffix identification | A to C (Non-emision) [Da (onemision) €,D&E Emission) Serial number 41395 ‘1487 48 Teling speed 600 t0 650 rev/min 650 to 750 rev/min 750 to 850 revimin Fast idle speed 1000 to 1200 rev/min 1100 t0 1300 rev/min 1200 ¢0 1250 rev/min Ignition timing, static and ‘dynamic at idling speed rev/min | 3° BTDC for use with 91 to | 3° BTDC for use with91 to | $° ATDC for use with 91 to | 93 research octane number | 93 research octane number | 93 rsearch octane number fuel, TDC for use with 85 | fuel TDC for use with AS | fuel, 8° ATDC for use with 8S ‘minimum research octane | minimum research octane | minimum research octane ‘number fuel number fuel number fuel ‘Vacuum Capsule | Advance only (connected) | Advance only (connected) | Advance & Retard (connected) Decelerating check with vacuum unit diconnected | ‘engine revimin (Crankshaft angle (Crankshaft angle Crankshaft angle | 44300 | 20st 21027" 2210 262 31800 231027" 18 t022° 1621" 1,800 1S to 19? | 1010 16° 25106." 400 ites? 61010" Ota 1,000 540° dws? po advance 600 3° below ro advance no advance Engine suffix iemtitication | F (Nonemision) | F cession) — European | F (Emission) ~ Australian ‘Serial number (6804 a1681A | area Idling speed $50 0 650 rev/min 700 19750 eex)min | #850 0 950 rev/min Fast idle speed | 1100 to 1300 rev/min 1100 to 1300 rev/min 1400 to 1500 rev/min Ignition timing, staticand | 6° BTDC for use with 91 10 |S ATDCfor use with 92 | §° ATDC for use with 92 dynamic at idle speed rev/min | 93 research octane number | Research oetane number fuel. | Research octane number fuel 2° BTDC for use with 85, | ‘minimum research octane £750 10800 rexjmin with | umber fuel, diverter valve) ‘Vacuum Capsule ‘Advance only (connected) | Advance & retard (connected) | Advance & retard (connected) Decelerating check with ‘uum unit disconnected engine revimin (Crankshaft angle Crankshaft angle | Crankshaft ansle 4,800, 24 t0 28 221026" 2210 26" 3,800 1021", | 17021", 800 251065" | 251068 1400 Ota wa? 1,000 No advance No advance ‘600 No advance No advance ‘continued 0s-s Engine Tuning Data Distributor 358 (continued) ELECTRONIC DISTRIBUTOR Make/type Rotation of rotor EUROPE AND AUSTRALIA 19.35:1 Compression ratio (Emission controlled) Engine prefix identification 11D (Emision) Seri number Idle speed Fast ile specd Ignition timing, static and dynamic at ling speed rev/min ‘Vacuum Capsule Deceleratng check with vacuum retard pipe disconnected engine r/min 3,600 3,080 2400 11200 ‘400 “41873 Gliding contact pe) 700 to 750 revimin 1150 to 1250 rev/min 6° BTDC for we with 97 research octane number fuel Advance & retard, retard disconnected Lucas 35DM ELECTRONIC Clockwise Engine prefix identification isp, 160,170, & 190 Distributor serial number Idle speed Fast idle speed Ignition timing, static and

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