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    9 views50 pages

    Land Rover Series III - Part 1 PDF

    Uploaded by

    Arley Ribeiro Silva

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 50
    INTRODUCTION The purpose of this manual is to assist skilled mechanics in the efficient repair and maintenance of the range of vehicles given on the title-page. 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 ‘The content pages list the titles and reference numbers of the divisions in alphabetical order. 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 British Leyland Motor Corporation and therefore continuity of the sumbering sequence is not maintained throughout the Each instruction within an operation has a sequence ‘number, and to complete the operation in the minimum time it is 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 a 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 Gomplete the operations described in the manual i also 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. To reduce repetition, operations covered in this manual do not include reference to testing the vehicle after repair. It is ‘essential that work is inspected and tested after completion and if necessary a road test of the vehicle is artied out particularly where sufety related items are Dimensions ‘The dimensions quoted are to design engineering specifi- cation, Alternative unit equivalents, shown in. brackets following the dimensions, have been converted from the anginal specification. uring the period of runningin from new, certain adjustments may vary from the specification figures given in this Manual. These adjustments will be re-set by the Distributor or Dealer at the After Sales Service, and thereafter should be maintained at the figures specified in the Manual. REPAIRS AND REPLACEMENTS. When replacement parts are required i genuine Land Rover replacements are used. ‘Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories: ‘Safety features embodied in the vehicle may be impaired if ‘other than genuine Land Rover replacements are fitted. In ‘certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer’ specification, Torque wrench setting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified, must be fitted. I theeicieney ofa fcking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling, abroad should ensure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing in theit ‘country of origin. The terms of the Owners Service Statement ‘may be invalidated by the fitting of other than genuine Land Rover paris. is essential that only All genuine Land Rover replacements have the full backing of ‘the Owners Service Statement, Land Rover Distributors and Dealers are obliged to supply only genuine Land Rover service parts. POISONOUS SUBSTANCES WARNING Many liquids and other substances used in motor vehicles fare 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 con- fined spaces i alo very explosive and fot. ‘When petol/easoline evaporates it produces 150 times its own volun invapear ich hen ig n diluted with air becomes a readily table mixture. The vapour is heavier than air and will always ll to the lowest level. It can readily be distributed throughout a ‘workshop by air current, consequently, even a small spillage of petrol/gasolineis potentially very dangerous Always have a fire extinguisher containing FOAM COx 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 dismantied all forms of ignition must be extinguished or removed, any head- lamps used must be flameproof and kept clear of spillage. NO ONE SHOULD BE PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH PETROL/ GASOLINE WITHOUT FIRST HAVING HAD SPECIA- LIST TRAINING. Fuel Tank Draining WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST IT IS STANDING OVER A PIT. Draining or extracting petrol/gasoline from vehicle fuel ten mut be cared out in well ventatd re, ‘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 regule- tions. 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 vehicles where the fuel line is secured to the fuel tank outlet by a spring stecl clip, it is recommended that such clips are released before the fuel line is disconnected of the fuel tank unit is removed. This procedure will avoid the possibility of residual petrol fumes in the fuel tank being ignited when the clips are released. ‘As “an added. precaution fuel tanks should have a PETROL/GASOLINE VAPOUR warning label attached to ‘them as soon as they are removed from the vehicle. continued 01-3 Pa ik Rene SE tama eo wees Raum a mae sant AERP, cate eos anc, wn eter ot a ot tea mae ee eee te cee e aae a Bplay Somat aeereny meee science mieten empty the tank. Immerse the tank completely in fa, Shiai dactmucitbaatae Eres cites shctetacte as ipa wrararviation Se ee EES eat scenes oe 01-4 Preliminary Pages es tee .o1 General Specification Date... ee ee . 04 Engine Tuning Data. eee os OS Torque Wrench Settings © 2. eee . 06 General Fitting Instructions... 2... fees +207 Recommended Service Lubricantsete. .. .. . . « bees 08 MAINTENANCE fee 10 ENGINE OPERATIONS — 2% litre 4 cylinder Petrol and Diesel Supplement for fvemain bearing engine atrearof mama 54, Camshaft ‘No. No. tence und rest Soe ee eee ee ee ee eng 12130 eet 2) —bearings--remove and refit 1213.13 12-3 Connecting rods and pistons removeandrefit..- 2... 2... 12.1701 12-4 Sovethaul os | pint Gooeo getaty tree Crankshaft ~iear oll seal-remove and refit. = 5. seen ee 122L20 0 12-10 remove and refit... ae P02 0123033 12 “overhaul Seer: Do 1122n46 12-11 Cylinder —head—remove and refit ce : 122910 12-14 overhaul 122918 12-17 essure check Petrol engite 1122501 12-13 —pressure check—Diesel engine 122501 12-23 Bide cover, front—remove and refit 122514 12-13 —side cover, rear—remove and refit 122516 12-13 Engine assembly—removeand refit. Ao 124101 12-25 Flywheel “remove and refit... 2. bee ee es 6125307 12-28 coverhaul ot See 22125310 12-28 starter ring gear—remove and refit ag SDI 1azs319 12-28 —spigot bearing-remove and refit’. |) | 12:53:20 12-28 on filter assembly, external—remove and refit = 12.60.01 —pump-remove and refit. = 12.60.26 —pump-overhaul a 521126032 sump-remove andreft 220° 222222220) lazeoaa Tappets-remove and refit. 2. ei! 229.57) Timing fear cover—remove and refit... oe + 1265.01 12-30 gear cover oil seal-remove and refit | DlLl LD laz6sos 12-30 ~geas—remove andrefit’ ed 2126522 12-32 “chain tensioner. pitt ut 12.65.28 12-34 Valve gear ‘remove and refit. oo ce 122034 12-21 “rocker shaft assembly—overhail” ee eer 12.29.55 12-23, ENGINE OPERATIONS ~ 2.6 litre 6 Cylinder Camshatt remove and refit se ee IRIBOL 12-36 Connecting rods and pistons Mremoveandteft es eee 2.1701 coratnaal 790 Cranksnatt “remove and refit. cece os. 122183 12-42 Toverhai | aie | 1242 continued 01-6 Operation No. bees =. 1221.20 eerie 2010) 558 aB0 1229.21 eee 12.25.01 Distributor and oil pump drive shaft E eeape al efit Se eet ee 12.10.22 Engine assembly Sjemove andrrefit 2 vee 124101 Exhaust valve rockers and shafts “remove and efits sw . 12.29.36 Flywheel remove and eit : 2s. 1283.07 operand eee ee er 11233.10 Inlet valve rockers and shafts Nemoveandrefit rs. oe eae . 122935 Toverhaul (replacing bushes)" 211222. t 2122985 Oil filter, external Mremoveand refit ee 126001 © pump remove and refit’... 6 ss « Beer izs06 overhaul Piiiiiis ee esears zeae Oil strainer “remove and refit beeen 12.60.20 Oil sump remove and refit... . eee ee ee 1260.44 Spigot bearing remove and refit... beens ». 12.53.20 Starter ring gear “remove and refit beens = 1253.19 ‘Timing chain and gears “remove and refit... . ee 1265.12 Timing chain tensioner Smove and he ee 9 1265.28 ‘Timing gear cover and oil seal Mfemove and relitcover oo ee ee ee eo 1265.01 Ttemove and refit ol seal eager 12.65.05 EMISSION CONTROL Emission Control System Description and Operations Air injection system Air pump-removeand refit... oe - 17.25.07 “Air pump drive bolt-remove and refit. | 11S 21 andsis Stensioning 2 I! 21173813 “Air ral/manifold—remove andrefit’ 221211211 175g “Antirunvon valve—check ne LL Dll limos Sremoveandreit’ 22) 2D t 1740.01 “Check vavecsemoveandrelt se 221222 Danas cists ee cece i iiiit 173522 “Description ofystem 22221221! D111 1725.00 Grankcase breathing system “Crankcase emission valve—remove and refit... . =. « 17.10.09 ii9 ts “overhaul G6 : Description of system eee =Engine breather filter—remove and refit, Aeon “Flame trap-removeandrefit. - - 2 Ss "Adsorption canister aout “Description of system ss ss pees continued Page ‘No. 12-41 12-44 12-46 12-44 12-36 12-50 12-48 12-81 12-81 12-47 12-50 12-52 12-82 12-52 12-82 12-83 12-52 12-51 12-54 12-85 12-53.» 12-53 ‘No, Exhaust emission control system Accelerator pump linkage setting ©... 2... 1. 17.20.00 —Carburetter adjustments ante 17:20-00 —Carburetter throttle prop~ remove and refit Dibil ll ir203s Description of system... Piliiiit 1720.00 Fuel filter-remove and refit Dil D Df 217038 Ignition system description and ignition timing © © << . : 17.20.00 ‘Throttle controlled vacuum switchcheck and adjust’ |. | 17:20.24 remove and refit, <> | 17.20.25 Exhaust Gas Recirculation (E.G-R.) system “Description of system. ee ee ae EGR valve-overhaul 12) 12112 fomoveand refit a -system clieck See Fault diagnosis FUEL SYSTEM NOTE: Where fuel system equipment has emission control features, refer to Division 17 of this Manual. Accelerator throttle controls arrangements. «5... . . . . . . 19.00.00 Aircleaner “remove and refit... Se ee 6 19.10.08 “clean and refill PEDDLE PDIP DDD Dl itot6 ‘Tamperproof carburetters : ce 5 19.15.00 Carburetter ‘remove and refit os see . + + 19.15.09 “overhaul and adjust 5 slg) Cold start control cable “remove and refit : : cee es 1920.26 Diesel fuel system general notes and arrangement cee ss 1900.00 Engine stop control cable “removeandrefit. 2... see 19.20.32 Fuel distributor/injection pump remove, set timing and refit... - +. 19.30.07 Fuel injectors remove and refit cs 5 19:60.01 spray check. | 19.60.02 overhaul PEPE Dt tlt 2 sess Fuel lft pump —remove and refit 19.45.09 ‘overhaul PEP DPD tlt lias Fuel filters~Refer to Maintenance Division 10 Fuel system priming ey 19.50.01 Fuel tank —removeandrefit ©... + 19.55.01 Fuel tank gauge unit—Refer to Division’ ‘Thermostat switeh “remove and refit, 19.15.50 Hand control, engine speed remove and refit 19.20.29 ‘Throttle linkage “remove and refit 19.20.07 COOLING SYSTEM Coolant drain and refill. Se ee + 2610.01 continued Page No. 17-8 17-8 17-10 17-8 7-01 17-9 17-10 17-10 17-12 17-12 17-12 17-13 17-2 19-16 19-2 19-17 19-18 19-24 1924 1925 19-21 19-21 19-22 19-23 19-16 19-17 19-16 26-1 01-7 ois Expansion tank “remove and refit Fan blades and pulley “remove and refit Radiator and front panel assembly—remove and refit Radiator “remove and refit, ‘Thermostat ‘remove and refit test Water pump ‘remove and refit, overhaul MANIFOLD AND EXHAUST SYSTEM Exhaust manifold, 26 litre models “remove and refit Exhaust system “front pipe-remove and refit... “intermediate pipe—remove and refit ”

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