Defender 90 110 Workshop Maunual 1

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TABLE OF' CONTENTS

SECTION
......................................................................................................
Introduction
General Specification Data ...................................................................................
Engine Tuning Data.. ..........................
.I!..............................................................
.....................................................................................
Torque Wrench Settings..

General Fitting Instructions
..................................................................................
Recommended Lubricants, Fluids and Capacities.. .....................................................

Maintenance .....................................................................................................
Engine .............................................................................................................
. ". . .
,~
..I
Fuel System (including Fuel Injection) .....................................................................

Cooling System ..................................................................................................
Clutch.. ............................................................................................................
Manual Gearbox and Transfer Box .........................................................................
Propeller Shafts.. ................................................................................................
Rear Axle and Final Drive ....................................................................................
BOOK
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Steering.. ..........................................................................................................
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Suspension ........................................................................................................
Brakes .............................................................................................................
Electrical ..........................................................................................................
BOOK ONE CONTENTS

Section
Number
Page
- Repairsand replacement parts

- Poisonous substances
-Fuel handling precautions
-Fuel tank draining and repair
-Service tools
- Location
El
of vehicle identification numbers
GENERAL SPECIFICATION DATA

-V8 engine data
-2.25 litre petrol engine data
-2.25 litre petrol engine data
-2.25 litre dicscl cnginc data
- 2.50 litre dicsel engine data
- General data -all models
- Tyrepressures
- Replacemcnt bulbs and units
-Vchiclc wcights
05
1
3
5
7
9
11
19
19
20
ENGINE TUNING DATA
ri
-V8 engine tuning data

- 2.25 litre petrol engine tuning data
litre petrol engine tuning data
- 2.25 and 2.50 litre dicscl engine tuning data
-2.5
.- .
06
TORQUE WRENCH SETINGS
.. ,..,.
...
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Book One Contents (contd)

Section
07
GENERAL FITTING INSTRUCTIONS

- Precautionsagainst damage
-Safetyprecautions
- Preparationand dismantling
- Inspectionof components
-Ball and roller bearings
- Oil seals
- Jointsand joint faces
-Flexible hydraulic pipes and hoses
-Metric bolt identification
- Metric nut identification
- Hydraulic fittings
- Keys and keyways
- Tabwashers, split pins, nuts and locking wire
- Screw threads
- Unified thread identification
1091
RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

- Recommendcd lubricants
- Anti-freeze
proportions
- Corrosion inhibitor
-Capacities
- Maintenance Schedules
- Maintenance- lubrication
- Maintenance-general maintenance and adjustments
1
1
1
2
2
2
3
3
3
4
4
5
5:
5
6
01
INTRODUCTION
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This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to
assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.
Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be
completed within t h e time stated in the 'Repair Operation Times'.
The Manual has been produced in separate books; this allows the information to be distributed throughout the
specialist areas of the modern service facility.
A table of contents in Book 1 lists the major components and systems together with the section and book numbers.
The cover of each book details the sections contained within that book.
The title page of each book carries the part numbers required to order replacement books, binders or complete
Service Manuals. This can be done through the normal channels.
REFERENCES
References to the left- or right-hand side in the manual are made when viewing the vehicle from the rear. With the
engine and gearbox assembly 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 carried out
particularly where safety related items are concerned.
DIMENSIONS
The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets
following the dimensions, have been converted from the original specification.
During the period of running-in 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 it is essential that only Land Rover parts are used.
Attention is particularly drawn to the following points concerning repairs and the fitting o f replacement parts and
accessories:
Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain
territories, legislation prohibits the fitting of parts not to the vehicle manufacturer's specification. Torque wrench
setting figures given in the Repair Operation Manual must bc strictly adhered to. Locking devices, where specified,
must be fitted. If the 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 location on the vehicle
conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement
may be invalidated by the fitting of other than Land Rover parts.
A11 Land Rover parts have the full backing of the Owners Service Statement.
Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts.
POISONOUS SUBSTANCES
Many liquids and other substances used in motor vehicles 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 petroI/gasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can
readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is
potentially very dangerous.
3
lo1I
Always have a fire extinguisher containing FOAM CO? GAS, o r POWDER close at hand when handling or draining
fuel, o r when dismantling fuel systems and in areas whcre fuel containers are stored.
Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system.
Whenever petroVgasoline is being handled, drained or stored, o r when fuel systems are being dismantled all forms of
ignition must be extinguished or removed, any hcad-lamps used must be flameproof and kept clear of spillage.
NO O N E SHOULD BE PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL/

GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.
FUEL TANK DRAINING

WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST
IT IS STANDING OVER A PIT.
Draining or extracting petrol/gasoline from vehicle fuel tank must be carried out in a well ventilated area.
The receptacle used to contain the petroVgasoline 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 PETROWGASOLINE HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK THE
PRECAUTIONS 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 steel clip, it is 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 are released.
As an added precaution fuel tanks should have a PETROUGASOLINE VAPOUR warning label attached to them
as soon as they are removed from the vehicle.
FUEL TANK REPAIR

Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering
the tank SAFE, by using one of the following methods:
STEAMING: With the filler cap and tank unit removed, empty the tank. Steam the tank for at least two hours
with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any
sediment and sludge not volatised by the steam, is washed out during the steaming process.
BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling
water containing an effective alkaline degreasing agent or a detergent, with t h e water filling and also
surrounding the tank for at least two hours.
After steaming o r boiling a signed and dated label to this effect should be attached to the tank
SPECIFICATION
Purchasers arc advised that the specification details set out in this Manual apply to a rangc of vehicles and not to any
one. For the specification of a particular vehicle, purchasers should consult their Distributor o r Dealer.
The Manufacturers reserve thc 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 Distributor or Dealer, by whom this Manual is supplied, shall in any circumstances be held
liable for any inaccuracy or the consequences thercof.
COPYRIGHT
@LandRover Limited 1984
All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any
form, electronic, mechanical, photocopying, recording or other means without prior written permission of Land
Rover Limited, Service Department, Solihull, England.
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Special Service Tools

The use of approved special service tools is important. They are essential if service operations
are to be carried out efficiently, and safely. The amount of time which they save can be
considerable.
Every special tool is designed with the close co-operation of Land Rover Ltd., and no tool is
put into production which has not been tested and approved by us. New tools are only
introduced where an operation cannot be satisfactorily carried out using existing tools or
standard equipment. The user is therefore assured that the tool is necessary and that it will
perform accurately, efficiently and safely.
Special tools bulletins will be issued periodically giving details of new tools as they are
introduced.
All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill.
Overseas orders should be placed with the local V. L. Churchill distributor, where one exists.
Countfies where there is no distributor may order direct from V. L. Churchill Limited. P.O.
Box 3, Daventry, Northamptonshire, England N N l l 4NF.
The tools recommended in this Workshop Manual are listed in a multi-language, illustrated catalogue obtainable
from Messrs. V. L. Churchill at the above address under publication number 2217/2/84 or from Land Rover Ltd.,
under part number LSM0052TC from thc following address, Land Rover Limited, Service Department, Lode Lane,
Solihull, West Midlands, England B92 8NW.
LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS

VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the

recommended maximum vehicle weights are stamped
on a plate riveted to the top of the brake pedal box in
the engine compartment.
The number is also stamped on the right-hand side of
the chassis forward of the spring mounting turret.
Always quote this number when writing to Land Rover
Limited.
Key to Vehicle Identification Number Plate
A
B
C
D
E
F
Type approval
VIN (minimum of 17 digits)
Maximum permitted laden weight for vehicle
Maximum vehicle and trailer weight
Maximum road weight -front axle
Maximum road weight -rear axle
ST
ENGINE SERIAL NUMBER

ENGINES
4 CYLINDER
The 4 cylinder engine number is stamped on a

machined surface at the front left-hand side of the
engine adjacent to the exhaust manifold front flange.
O n later engines the number is stamped above the rear
side cover, as the second illustration shows.
TOO1
fAND
&IR
ST037
ENGINE SERIAL NUMBER -VS ENGINE
The V8 engine serial number is stamped on a cast pad

on the cylinder block between numbers 3 and 5
cylinders.
6
6
-.-
LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS
01
ST664M
TRANSFER GEARBOX LT230T - 4 CYLINDER

AND V8 VEHICLES FROM SERIAL NUMBER
SUFFIX B ONWARD
ST663M
FRONT AXLE
Stamped on top of the left-hand axle tube.

REAR AXLE
Stamped on rear of left-hand axle tube.

MAIN GEARBOX LT77 -4 CYLINDER VEHICLES
Stamped on a pad on the right-hand side of the gearbox

immediately below the oil filler level plug.
MAIN GEARBOX LT85 FIVE SPEED
VEHICLES
V8
Stamped on the right-hand side of the front bearing

plate.
ST665M
TRANSFER GEARBOX LT230R

VEHICLES
-4
CYLINDER
Stamped on the casing on the left-hand side of the

gearbox below the mainshaft rear bearing housing
adjacent to the bottom cover.
STl546M
..
ENGINE
Type .................................................................
Number of cylinders .............................................
Bore .................................................................
Stroke ...............................................................
Capacity ............................................................
Valve operation.. .................................................
Maximum power- B.H.P .....................................
Maximum power -KW.. ......................................
Maximum torque .................................................
'13
at 4000rpm
84.6
251 Nm (185 lb ft) at 2500 rpm
Crankshaft
Main journal diameter .......................................
Minimum regrind diameter ..............................
Crankpin journal diameter. .................................
Crankshaft end thrust ........................................
Crankshaft 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 - 1.9605in)
Taken on thrust washers of centre main bearing
0,lO - 0,20 m m (0.004 - 0.008 in)
Main bearings
Number and type ..............................................
Material .........................................................
Diametrical clearance ........................................
Undersizes ......................................................
5 , Vandervell shells
Lead-indium
0,010 - 0,048 mm (0.0004 - 0.0019 in)
0,254 mm, 0,508 mm (0.010 in, 0.020 in)
Connecting rods
Type.. ............................................................
Length between centres ......................................
Horizontally split big end, pIain small end

143,81 - 143,71 mm (5.662 - 5.658 in)
Big end bearings

Type and material .............................................
Diametrical clearance .......................................
End-float on crankpin .......................................
Undersizes ......................................................
Vandervell VP lead-indium
0,015 - 0,055 mm (0.0006 - 0.0022 in)
0,15 - 0,36 mm (0.006 - 0.014 in)
0,254 mm, 0,508 mm (0.010 in, 0.020 in)
04
V8
Eight, two banks of four
88,90 mm (3.500 in)
71,12 mm (2.800 in)
3528 cc (215 in')
Overhead by. push-rod
_
Gudgeon pins
Length ...........................................................
Diameter ........................................................
Fit-in connecting rod .........................................
Clearance in piston ............................................
Pistons
Clearance in bore measlured at hottom of skirt at
right angles to gudgeon pin ..................................
72,67 - 72,79 mm (2.861 - 2.866 in)

22,215 - 22,22 mm (0.8746 - 0.8749 in)
Press fit
0,002 - 0,007 mm (0.0001 - 0.0003 in)
0,018 - 0,033 mm (0.0007 - 0.0013 in)
1041
Piston rings
Number of compression .....................................
Number of oil ..................................................
No. 1 compression ring .......................................
No. 2 compression ring.. .....................................
Width of compression rings .................................
Compression ring gap ........................................
Oil ring type ....................................................
Oil ring width. ..................................................
Oil ring gap .....................................................
2
1
Chrome parallel faced
Stepped to 'L' shape and marked 'T' or 'TOP'
1,56 - 1,59 mm (0.0615 - 0.0625 in)
0,44 - 0,57 mm (0.017 - 0.022 in)
Perfect circle, type 98-6
4,811 mm (0.1894 in) max
0,38 - 1,40 mm (0.015 - 0.055 in)
Camshaft
Location .........................................................
Bearings .........................................................
Number of bearings ...........................................
Drive .............................................................
Central
Non-serviceable
5
Chain 9,52 mm (0.375 in) pitch x 54pitches
Valves
Length:
Inlet ...........................................................
Exhaust.. .....................................................
Seat angle:
Inlet ...........................................................
Exhaust.. .....................................................
Head diameter:
Inlet ...........................................................
Exhaust.. .....................................................
Stem diameter:
inlet ...........................................................
Exhaust .......................................................
Stem t o guide clearance:
Inlet ...........................................................
Exhaust .......................................................
Valve lift (inlet and exhaust). ...............................
Valve spring length fitted ....................................
0,025 - 0,066 mm (0.0010 - 0.0026 in)

0,038 - 0,078 mm (0.0015 - 0.0031 in)
9,49 mm (0.374 in)
40,4 mm (1.590 in) at pressure of 2 9 3 kg (65 lbs)
Lubrication
System ...........................................................
System pressure, engine warm at 2400 rpm .............
Oil filter (external). ...........................................
Oil filter (internal) ............................................
Oii pump type ..................................................
Wet sump, pressure fed

2 , l - 2,8 kgf cm2 (30 - 40 Ibf in2)
Full-flow, self-contained cartridge
Gauze. Pump intake filter
Gear
Oil pressure reIief valve

Type ..............................................................
Relief valve spring:
Free length ...................................................
Compressed length at 4,2 kg (9.3 lb) load ............
Oil filter by-pass valve

Type ...............................................................
By-pass valve spring:
Free length ...................................................
Compressed length at 0,34 kg (0.75 lb). ...............
116,59 - 117,35 mm (4.590 - 4.620 in)

116,59 - 117,35 mm (4.590 - 4.620 in)
39,75 - 40,OO mm (1.565 - 1.575 in)

34,226 - 34,480 mm (1.3475 - 1.3575 in)
8,664 - 8,679 mm (0.3411 - 0.3417 in)
8,651 - 8,666 mm (0.3406 - 0.3412 in)
Non-adjustable
81,2 mm (3.2OO in)
45,7 m m (1.800 in)
Non-adjustable
37,5 mm (1.48 in)
22,6 mm (0.89 in)
......
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2.25 LITRE PETROL ENGINE
.....
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ENGINE
Type .................................................................
Bore .................................................................
Stroke ...............................................................
Capacity ............................................................
Valve operation. ..................................................
Compression ratio.. ..............................................
Maximum power @ 4000 rpm .................................
Maximum torque @ 2000 rpm.. ...............................
90,47 mm (3.562 in)

88,9mm (3.500 in)
2286 cm3 (139.500 in3)
Overhead by push-rod
8.0: 1
55.2 Kw (74 bhp)
163 Nm (120 Ibf ft)
Crankshaft
Crankpin journal diameter ..................................
63,487 - 63.500 mm (2.4995 - 2.500 in)

63,246 - 63,2333 mm (2.4900 - 2.4895 in)
58,725 - 58,744 mm (2.312 - 2.31275 in)
58,48985 - 58,47080 mm (2.30275 - 2.30200 in)
Taken on thrust washers at centre main bearing
0,05 .0 3 m m (0.002 - 0.006 in)
Main bearings
Number and type ..............................................
Material .........................................................
Undersizes ......................................................
5 halved shells
Steel shell, tin-aluminium lined
0,020 - 0,063 mm (0.0008 - 0.0025 in)
0,25 mm (0.010 in)
Connecting rods
Type ..............................................................
Length between centres.. ....................................
Horizontally split big end, plain small end

175,36 - 175,46 mm (6.904 - 6.908 in)
Big end bearings

End-float on crankpin ........................................
Undersizes ......................................................
Steel shell, copper-lead lined

0,019 - 0,068 mm (0.00075 - 0.0027 in)
0,20 - 0,30 mm (0.007 - 0.012 in)
0,25 mm (0.010 in)
Gudgeon pins
Type ..............................................................
Fit in piston .....................................................
Clearance in connecting rod ................................
Floating
Push fit by hand
0,007 - 0,015 mm (0.0003 - 0.0006 in)
Pistons
Type 8.O:l compression ratio ...............................
Clearance in bore, measured at bottom of skirt at
right angles to gudgeon pin:
Standard size pistons ......................................
Oversize pistons ............................................
Aluminium alloy, flat top

0,06 - 0,07 mm (0.0023 - 0.0027 in)
0,043 - 0,055 m m (0 0017 - 0 0022 in)
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4 cylinder
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Piston rings
Compression ...................................................
Gap in bore ..................................................
Clearance in groove.. ......................................
Oil control ......................................................
Gap in bore ..................................................
2
0,38 - 0 3 0 mm (0.015 - 0.020 in)
0,046 - 0,097 mm (0.0018 - 0.0038 in)
1
0,38 - 0,50 mm (0.015 - 0.020 in)
0,038 - 0,089 mm (0.0015 - 0.0035 in)
Camshaft
Location .........................................................
End-float ........................................................
Material .........................................................
Drive .............................................................
Right-hand side (thrust side) of engine

0,06 - 0,13 mm (0.0025 - 0.0055 in)
4
Steel shell, white metal lined
Chain
Valves
Length:
Inlet ...........................................................
Exhaust.. .....................................................
Seat angle:
Inlet ...........................................................
Exhaust .......................................................
Head diameter:
Inlet ...........................................................
Exhaust .......................................................
Stem diameter:
Inlet ...........................................................
Exhaust.. .....................................................
Stem to guide clearance:
Inlet ...........................................................
Exhaust.. .....................................................
Valve lift:
Inlet ...........................................................
Exhaust.. .....................................................
Valve springs
Type.. ............................................................
Inner:
Length, free .................................................
Length, under 8,O kg (17.7 Ib) load ....................
Outer:
Length, free .................................................
Length, under 21 kg (46 lb) load.. ......................
Lubrication
System ...........................................................
Oil pump: Early type
Type ...........................................................
Drive ..........................................................
End-float of gears:
Steel gear .....................................................
Aluminium gear ............................................
Radial clearance of gears .................................
Backlash of gears.. .........................................
111,20 - 111,66 mm (4.378 - 4.396 in)

111,22 - 111,58 mm (4.388 - 4.412 in)
30"
45"
44,32 - 44,57 mm (1.744 - 1.755 in)
34,93 - 35,18 mm (1.378 - 1.380 in)
7,899 - 7,912 mm (0.3109 - 0.3115 in)
8,682 - 8,694 mm (0.3418 - 0.3422 in)
0,033 - 0,048 mm (0.0013 - 0.0019 in)
0,058 - 0,073 mm (0.0023 - 0.0029 in)
10,236 mm (0.403 in)
9,85 mm (0.388 in)
Duplex interference coil

42,67 mm (1.680 in)
37,13 mm (1.462 in)
46,28 mm (1.822 in)
40,30 mm (1.587 in)

2,45 - 4,50 kgf cm2 (35 - 65 lbf in2)
Double gear
SnlinPc!
-r----- shaft frnm c m s h a f t skew gear
0,05 - 0,12 mm (0.002 - 0.005 in)

0,07 - 0,15 m m (0.003 - 0.006 in)
0,02 - 0,lO m m (0.001 - 0.004 in)
0,15 - 0,28 mm (0.006 - 0.012 in)

......
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Lubrication (continued)
Oil pump: Latest type
Type ...........................................................
Drive ..........................................................
End-float of both gears .......................................
Oil pressure relief valve

Type ..............................................................
Full length ....................................................
Compressed length at 2,58 kg (5.7 lb) load ...........
Double gear, 10 teeth, sintered iron gears

Splined shaft from camshaft skew gear
0,026 0,135 mm (0.0009 - 0.0045 in)
0,025 - 0,075 mm (0.0008 - 0.0025 in)
0,l - 0,2 mm (0.0034 - 0.0067 in)
Non-adjustable
67,82 mm (2.670 in)
61,23 mm (2.450 in)
2.5 LITRE PETROL ENGINE
,L . .
ENGINE
Type .................................................................
Bore .................................................................
Stroke ...............................................................
Capacity ............................................................
Valve operation.. .................................................
Maximum power @ 4000 rpm .................................
Maximum torque @ 2000 rpm.. ...............................
Commencing serial no.. .........................................
4 cylinder
90,47 mm (3.562 in)
97 mm (3.82 in)
2495 cm3 (152.25 in3)
8.0: 1
59.5 Kw (80 bhp)
175 Nm (129 Ibf ft)
17H00011C
Crankshaft
Crankshaft end-float.. ........................................
63,487 - 63,500 mm (2.4995 - 2.500 in)

63,246 - 63,2333 mm (2.4900 - 2.4895 in)
58,725 58,744 mm (2.312 - 2.31275 in)
58,48985 - 58,47080 mm (2.30275 - 2.30200 in)
0,05 - 0,15 mm (0.002 - 0.006 in)
Main bearings
Number and type ..............................................
Material .........................................................
Undersizes ......................................................
5 halved shells
Copper-lead lined
0,018 - 0,06 mm (0.0007 - 0.0026 in)
0,25 mm (0.010 in)
Connecting rods
Type ..............................................................

175,36 - 17546 mm (6.904 - 6.908 in)
Connecting rod bearings

Undersizes ......................................................

0,025 - 0,075 mm (0.001 - 0.003 in)
0,20 - 0,30 mm (0.007 - 0.012 in)
0,25 mm (0.010 in)
104I
104
GENERAL SPECIFICATIONDATA
Gudgeon pins
Type ..............................................................
Fit in piston .....................................................
Floating
Push fit by hand
0,007 - 0,015 mm (0.0003 - 0.0006 in)
Pistons
Type 8.0:1 compression ratio ...............................
Clearance in bore measured @ 17 mm from bottom
of skirt at right angles to gudgeon pin:
Standard and oversize pistons ...........................
0,043 - 0,067 mm (0.0017.- 0.0026 in)
Piston rings
Compression ...................................................
Gap in bore ..................................................
Clearance in groove ........................................
Oil control ......................................................
Gap in bore ..................................................
2
0,40 - 0,65 mm (0.016 - 0.026 in)
0,046 - 0,097 m m (0.0018 - 0.0038 in)
1
0,30 - 0,55 mm (0.012 - 0.022 in)
0,026 - 0,076 mm (0.0012 - 0.003 in)
Camshaft
Location .........................................................
End-float ........................................................
Material .........................................................
Drive .............................................................

0,06 - 0,13 mm (0.0025 - 0.0055 in)
4
76 link chain
Valves
Length :
Inlet ...........................................................
Exhaust.. .....................................................
Seat angle:
Inlet ...........................................................
Exhaust.. .....................................................
Head diameter:
Inlet ...........................................................
Exhaust.. .....................................................
Stem diameter:
Inlet ...........................................................
Exhaust,. .....................................................
Inlet ...........................................................
Exhaust .......................................................
Valve lift:
Inlet ...........................................................
Exhaust .......................................................
Exhaust valve seat insert:
External diameter.. ........................................
Internal diameter.. .........................................
Width .........................................................
Seat angle and depth .......................................
Aluminium alloy. Recessed crown.
111,20- 111,66mm (4.377 -4.396in)

11 1,12 - 111 3 9 mm (4.374 - 4.393 in)
30"
45"
44,32 - 44,58 mm (1.744 - 1.755 in)
34,43 - 34,18 mm (1.355 - 1.345 in)
7,899 - 7,912 mm (0.3109 - 0.3115 in)
8,697 - 8,679 mm (0.3424 - 0.3416 in)
0,033 - 0,048 mm (0.0013 - 0.0019 in)
0,035 - 0,076 mm (0.0014 - 0.0022 in)
10,236 mm (0.403 in)
9,85 mm (0.388 in)
36,576 - 36,601 (1.440 - 1.441 in)
28,448 - 28,702 mm (1.120 - 1.130 in)
5,055 - 5,105 mm (0.199 - 0.201 in)
45". 0,635 - 0,889 iiiiii ( 0 . m - 0.035 in;
,,:?.%
.... 7
Valve springs
Type ..............................................................
Inner:
Length, free ................................................
Length, under 8,0 kg (17.7 Ib) load ....................
Outer:
Length, free .................................................
Length, under 21 kg (46 Ib) load ........................
Lubrication
System ...........................................................
Oil pump:
Type ...........................................................
Drive ..........................................................
End-float of both gears.. .....................................
Backlash of gears ...........................................
- .
1041
Duplex interference coil

42,67 mm (1.680 in)
37,13 mm (1.462 in)
46,28 mm (1.822 in)
40,30 mm (1.587 in)

2,45 - 4,50 kgf cm2 (35 - 65 Ibf in2)
0,026 - 0,135 mm (0.0009 - 0.0045 in)
0,025 - 0,075 mm (0.0008 - 0.0025 in)
0,l - 0,2 mm (0.0034 - 0.0067 in)
...

Type ..............................................................
Full length ....................................................
Compressed length at 2,58 kg (5.7 lb) load ...........
Non-adjustable
67,82 m m (2.670 in)
61,23 mm (2.450 in)
2.25 LITRE DIESEL ENGINE
ENGINE
Type .................................................................
Bore .................................................................
Stroke ...............................................................
Capacity ............................................................
Valve operation. ..................................................
Maximum power .................................................
Maximum torque .................................................
4 cylinder
90,47 mm (3.562 in)
88,9 mm (3.500 in)
2286 cm3 (139 in3)
23:l
44Kw (59 bhp) at 4000 rpm
136 N m (100 Ibf ft) at 1800 rpm
Crankshaft
Main bearing journal diameter.. ...........................
Regrind dimensions:
63,246 - 63,2333 mm (2.490 - 2.4895 in) ...............
Regrind dimensions:
58,48985 - 58,4708 mm (2.30275 - 2.30200 in). .......
Use 0.010 in U/S bearings

0,05 - 0,15 mm (0.002 - 0.006 in)
Main bearings
Number and type ..............................................
Material .........................................................
5 halved shells
Steel shell, copper-lead lined, tin plated
0,020 - 0,063 mm (0.0008 - 0.0025 in)
63,487 - 63,500 mm (2.4995 - 2.500 in)

58,725 - 58,744 mm (2.312 - 2.31275 in)
-.
Connecting rods
Type ..............................................................

175,38 - 175,43 mm (6.905 - 6.907 in)
Big end bearings

End-float on crankpin. .......................................

0,020 - 0,0635 mm (0.0008 - 0.0025 in)
0,15 - 0,356 mm (0.006 - 0.014 in)
Gudgeon pins
Type ..............................................................
Fit in piston .....................................................
Diameter ........................................................
Floating
Push fit by hand
0,0196 - G,0036 mm (0.0007 - 0.00014 in)
30,1564 - 30,1625 mm (1.18726 - 1.1875 in)
Pistons
Type.. ............................................................
Clearance in bore, measured at bottom of skirt at
right angles to gudgeon pin:
Standard size pistons ......................................
Oversize pistons ............................................
Piston rings
Compression No. 1 (top):
Type ...........................................................
Gap in bore ..................................................
Compression Nos. 2 and 3:
Type ...........................................................
Gap in bore ..................................................
Oil control No. 4:
Type ...........................................................
Gap in bore ..................................................
Valves
Length:
Inlet ...........................................................
Exhaust.. .....................................................
Seat angle:
Inlet ...........................................................
Exhaust .......................................................
Head diameter:
Inlet ...........................................................
Exhaust.. .....................................................
Stem diameter:
Inlet ...........................................................
cxnausr .......................................................
Inlet ...........................................................
Exhaust.. .....................................................
Valve lift:
Inlet ...........................................................
Exhaust .......................................................
Aluminium alloy, with V shape recess in crown
0,111 - 0,134 mm (0.0044 -0.0053 in)

0,111 - 0,157 mm (0.0044 - 0.0062 in)
Square friction edge, chrome plated

0,35 - 0,50 mm (0.014 - 0.019 in)
0,06 - 0,11 mm (0.0025 - 0.0045 in)
Bevelled friction edge. Marked 'T' or 'TOP' on upper side
0,25 - 0,38 mm (0.010 - 0.015 in)
0,06 - 0,11 mm (0.0025 - 0.0045 in)
Ring and spring
0,279 - 0,406 mm (0.011 - 0.016 in)
0,038 - 0,064 mm (0.0015 - 0.0025 in)
116,26 - 116,51 mm (4.377 - 4.587 in)

116,79 - 117,25 mm (4.598 - 4.616.in)
45"
45"
39,12 - 39,37 mm (1.540 - 1.550 in)
33,25 - 33,50 mm (1.309 - 1.318 in)
7,912 - 7,899 mm (0.3114 - 0.3109 in)
8,682 - 8,694 mm (0.3418 - 0.3422 in)
0,033 - 0,048 mm (0.0013 - 0.0019 in)
0,058 - 0,073 mm (0.0023 - 0.0029 in)
9,85 m m (0.388 in)
10,26 mm (0.404 in)

Camshaft
Location .........................................................
End-float ........................................................
Material .........................................................
Drive .............................................................
Valve springs
Type ..............................................................
Inner:
Length, free .................................................
Length, under 8,O kg (17.7 Ib) load ....................
Outer:
Length, free .................................................
Length, under 21 kg (46 Ib) load ........................
*...
,....
Lubrication
System ...........................................................
Oil pump:
Type ...........................................................
Drive ..........................................................
End-float of gears:
Steel gear .....................................................
. .
Aluminium gear ............................................
......................
Radial clearance of gears .....
Backlash of gears ...............................
104I

0 , l - 0,2 mm (0.004 - 0.008 in)
4
Chain
Duplex Interference double coil

42,67 mm (1.680 in)
40,30 mm (1.587 in)
46,28 mm (1.822 in)
40,30 mm (1.587 in)

2,5 - 4,57 kgf cm2 (35 - 65 Ibf in2)
Double gear
0,05 - 0,12 mm (0.003 - 0.005 in)
0,07 - 0,15 mm (0.003 - 0.006 in)
0,02 - 0,lO mm (0.001 - 0.004 in)
0,15 - 0,28 mm (0.006 - 0.012 in)

Type ..............................................................
Non-adj ust able
Relief valvc spring:
Full length ....................................................
67,82 mm (2.670 in)
Compressed length at 2,58 kg (5.7 Ib) load ........... 61,23 mm (2.450 in)
2.5 LITRE DIESEL ENGINE
...
ENGINE
Number of cylinders .............................................
Bore .................................................................
Strokc ...............................................................
Capacity ....................
.......................
Compression ratio. ...............................................
Piston area (total) ........
.................................
Maximum power at 4000
.......................
Maximum torque at 1800 rpm ...........................
. .
Crankshaft
Main bearing journal diameter.. ...........................
Regrind dimensions:
63,246 - 63,2333 mm (2.490 - 2.4895 in). ..............
Regrind dimensions:
58,48985 - 58,4708 mm (2.30275 - 2.30200 in) ........
Crankshaft end-float..........................................
4
90,47 mm (3.562 in)
97,OO mm (3.819 in)
2495 cc
21:l
257,l cm3 (39.86 in3)
65.5 bhp
113 Ibf ft
63,487 - 63,500 mm (2.4995 - 2.5000 in)

58,725 - 58,744 mm (2.312 - 2.31275 in)
0,05 - 0,15 mm (0.002 - 0.006 in)
9
04
Main bearings
Number and type.. ............................................
5 halved shells
0,018 - 0,061 mm (0.0007 - 0.0024 in)
Connecting rods
Length between centres.. ....................................
Diametrical clearance (big-end bearings). ...............
175,38 - 175,43 m m (6.905 - 6.907 in)

0,025 - 0,075 mm (0.001 - 0.003in)
0,15 - 0,356 mm (0.006 - 0.014 in)
Pistons
Type ..............................................................
Skirt diametrical clearance (at right
angle to gudgeon pin) ........................................
0,025 - 0,05 mm (0.001 - 0.002in)
Gudgeon pins
Type ..............................................................
Fit in piston .....................................................
Diameter ........................................................
Floating
Hand push fit
30,1564 - 30,1625 mm (1.18726 - 1.18750 in)
0,0196 - 0,0036 mm (0.00077 - 0.00014 in)
Piston rings
Type: Top ...................................................
Second ...............................................
Oil control ..........................................
Square friction edge, chrome plated

Taper faced
Expander and rails
Camshaft
Drive .............................................................
Location .........................................................
End-float ........................................................
Number of bearings.. .........................................
Material .........................................................
25,4 mm (0.1 in) wide dry toothed belt

Right-hand side (thrust side)
0 , l - 0,2 mm (0.004 - 0.008 in)
4
Valves
Seat angle:
Inlet ...........................................................
Exhaust .......................................................
Head diameter:
Inlet ...........................................................
Exhaust .......................................................
Valve lift:
Inlet ...........................................................
Exhaust .......................................................
Cam lift:
Inlet ...........................................................
Exhaust .......................................................
Stem diameter:
inlet ...........................................................
Exhaust.. .....................................................
...
.....
'' ?I
.::'
'!
......
1.
Aluminium alloy 'V' shaped valve recess in crown
45"
45"
39,12 - 39,37 mm (1.540 - 1.550 in)
33,25 - 33,50 m m (1.309 - 1.319 in)
9,85 mm (0.388 in)

10,26 m m (0.404 in)
6,81 mm (0.268 in)
7,06 mm (0.278 in)
7,912 - 7,899 mm (0.3114 - 0.3109 in)
8,682 - 8,694miii (0.3418 - 0.3422 in)

.,: -, Valve springs
Type ..............................................................
Inner:
Length, free .................................................
Length, under 8,O kg (17.7 lb) load ....................
Outer:
Length, free .................................................
Length, under 21 kg (46 lb) load ........................
,
.
.
a
-
r,y;:.:;>:!
.r':."'"
.._
..,..I
- .._ .
. .A<?.. .,_ ,
':
........
::
. .:;,,
.
,1
Duplex Interference double coil

42,67 mm (1.680 in)
40,30 mm (1.587 in)
46,28 mm (1 A22 in)
40,30 mm (1.587 in)
Lubrication
System ...........................................................
System pressure, engine warm at 2000 rpm ............. 2,5 - 4,57 kgf cm2 (35 - 65 Ibf in2)
Oil pump: Early type
Type ...........................................................
Double gear
Drive ..........................................................
End-float of gears:
Steel gear .....................................................
0,05 - 0,12 mm (0.002 - 0.005 in)
Aluminium gear ............................................
0,07 - 0,15 mm (0.003 - 0.006 in)
0,02 - 0,lO mm (0.001 - 0.004 in)
0,15 - 0,28 mm (0.006 - 0.012 in)
Oil pump: Latest type
Type ...........................................................
Drive ..........................................................
0,026 - 0,135 mm (0.0009 - 0.0045 in)
End-float of both gears.. .....................................
0,025 - 0,075 mm (0.0008 - 0.0025 in)
0,l - 0,2 mm (0.0034 - 0.0067 in)
Backlash of gears ...........................................
~

Type ..............................................................
Full length ....................................................
Compressed length at 2,58 kg (5.7 Ib) load ...........
Non-adjustable
67,82 mm (2.670 in)
61,23 mm (2.450 in)
GENERAL DATA
.:.r9
.....
FUEL SYSTEM -2.25 Petrol

Carburetter ........................................................
Air cleaner.. .......................................................
See 'ENGINE TUNING DATA'

Oil bath with built-in centrifugal pre-cleaner
Fuel pump -Early Models

Type ..............................................................
Pressure range .................................................
Mechanical with sedimcnt bowl and hand primer

3 - 5 psi
Fuel pump -Latest Models

Make and Type ................................................
Pressure range .................................................
Facet, electric. Mounted on R.H. side of chassis

3 - 5 psi
FUEL SYSTEM -2.25 and 2.5 Diesel

Injection pump.. ..................................................
Fuel lift pump type ...............................................
Pressure range ....................................................

Mechanical, with hand primer
0,35 - 0 3 6 kgf cm2 ( 5 - 8 Ibf ft2)
11
104I
FUEL SYSTEM VS engine

Carburetter ........................................................
Fuel pump - Make,type ......................................
Air cleaner.. .......................................................
See ENGINE TUNING DATA

Facet, electric mounted vertically on R.H. side of chassis
Cyclonc, replaceable element
COOLING SYSTEM 2.25 Petrol, 2.25 and 2.5 Diesel

Type.. ...............................................................
Pressurized spill rcturn system with thermostat control,

pump and fan assisted
82C
0,6 kgf cm2 (9 lbf in)
Centrifugal
Thermostat ........................................................
Pressure cap .......................................................
Type of pump .....................................................
COOLING SYSTEM - VS engine
Type.. ...............................................................
Thermostat ........................................................
Type of pump .....................................................
Pressurized spill return system with thermostat control,

pump and fan assisted
Emission and non-emission 82C, Australia 88C
Centrifugal
CLUTCH -2.25 Petrol

Type .................................................................
Centre plate diameter ...........................................
Facing material ...................................................
Facing material identification colour ........................
Number of damper springs .....................................
Damper spring colour ...........................................
Clutch release bearing. ..........................................
Borg and Beck diaphragm spring

242,l mm (9.500 in)
Raybestos 1488-05
Whitdviolet on pcriphary
6
Dark grey/light green
Ball journal
CLUTCH 2.25 and 2.5 Diesel engine -Early type

Type.. ...............................................................
Facing material ...................................................
Damper spring colour.. .........................................
Clutch release bearing.. .........................................

CLUTCH -Later type
Type.. ...............................................................
Centre plate diameter (friction plate) .......................
Facing material ...................................................
Clutch release bearing.. .........................................

CLUTCH - VS engine
Type .................................................................
Facing material ...................................................
Release bearing.. .................................................
Number of damper springs.. ...................................
12
Verto diaphragm spring

242,l mm (9.500 in)
Raybestos 1488-05
8
2 off white/green
2 off pigeon blue
4 off ruby red
Ball journal
Verto diaphragm spring

235 mm (9.25 in)
Verto 791
8
2 off white/green -suffix C
2 off pigeon blue -suffix A
4 off ruby red -suffix B
Ball journal
Borg and Beck diaphragm spring

267 mm (10.5 in)
Raybestos 1488-05. Grooved. Whitehiolet
Light blue/dark blue
Ball journal
c.....
04
.......
.,- ,..
.........
4 c,:.
i.
^.
-;
;, .d
.....
..,,
.>,.,.
3:.
Main gearbox
Type LT77 ......................................................
Speeds ...........................................................
Synchromesh ...................................................
Ratios:
Fifth ...........................................................
Fourth (direct) ..............................................
Third ..........................................................
Second ........................................................
First. ...........................................................
Reverse .......................................................
Transfer box
Type LT230R ..................................................
...
.. .
...
Ratios:
. High ...........................................................
Low ............................................................
Overall ratios (final drive):
Fifth ...........................................................
Fourth.. .......................................................
Third ..........................................................
Second ........................................................
First,. ..........................................................
Reverse .......................................................
Input gear .......................................................
Intermediate gear .............................................
Output gear.. ...................................................
Single helical constant mesh
5 forward 1 reverse
All forward speeds
0.8314:l
1.0000:1
1.5074:l
2.3008: 1
3.5850: 1
3.7007:l
Two-speed reduction on main gcarbox output.

Front and rear drive permanently engaged via a lockable
differential
1.6670
3.3198
In high transfer
4.9042: 1
5 3987: 1
8.8917: 1
13.5715:l
21.1472:l
21.8293:l
26 Teeth
19 x 41 x 35 Tceth
40 x 37 Teeth
In low transfer
9.7666:l
11.7471:1
17.7075:1
27.0272: 1
42.1138: 1
43.4723:l
....
..
TRANSMISSION V8 Engine
Main gearbox
Type LT95 ......................................................
Speeds ...........................................................
Synchromesh ...................................................
Ratios:
Fourth (direct) ..............................................
Third ..........................................................
Second ........................................................
First ............................................................
Reverse .......................................................
Transfer box
Type LT95 ......................................................
. ,. .
Ratios:
High ...........................................................
Low ............................................................
Overall ratios (final drive):
Fourth.. .......................................................
Third ..........................................................
Second ........................................................
First.. ..........................................................
Reverse .......................................................
Single helical constant mesh

4 forward 1 reverse
All forward speeds
1.0000:1
1.5049: 1
2.4480: 1
4.0691:1
3.6643:l
Two-speed reduction on main gearbox output.

differential
1.3362
3.3206
In high transfer
4.7281 :1
7.1 154:1
11S74.5: 1
19.2390:1
27.3250: 1
In low transfer
11.7497:1
17.6822:l
28.7634: 1
47.8101:l
43.0538:l
13
04
TRANSMISSION Ninety and One Ten VS with 5-speed gearbox

Main gearbox
Type -Manual.. ..............................................
LT85 5-speed helical constant mesh, with synchromesh
on all forward gears
Main gearbox ratios.. .........................................
Fifth (Cruising
gear)
0.7951
Fourth
1.oooo
Third
1.4362
Second
2.1804
First
3.6497
Reverse
3.8242
Transfer gearbox
Type.. ............................................................
-Ninety models ...........................................
_One Ten models ........................................

Overall ratio (including final drive) - Ninety models
LT230T. Two-speed reduction on main gearbox output.

differential.
High
1.1923
Low
3.3198
High
1.410
Low
3.3198
In high transfer
In low transfer
Fifth (Cruising
3.3544
9.3401
gear)
Fourth
4.2189
11.7471
Third
16.8712
6.0592
Second
9.1989
25.6134
First
15.3977
42.8734
Reverse
44.9233
16.1339
Overall ratio (including final drive)

-One Ten models
Fifth (Cruising
gear)
Fourth
Third
Second
First
Reverse
In high transfer
In low transfer
3.9695
4.9925
7.1702
10.8856
18.2210
19.0922
9.3401
11.7471
16.8712
25.6 134
42.8734
44.9233
REAR AXLE One Ten only

Type .................................................................
Ratio ................................................................
Track ................................................................
Salisbury 8HA
3.538
1485,90 mm (58.50 in)
FRONT AXLE -All models and Ninety rear

Type.. ...............................................................
Ratio ................................................................
Spiral bevel, enclosed constant velocity joints

3.538
PROPELLER SHAFTS -All Models

Type: Front and rear ............................................
14
Single Hookes universal needle roller joints. Sliding

portion on front shaft gaiierea, rear shaft open

*/-:
:**
SUSPENSION -All Models

Type .................................................................
Front
................................................................
Rear .................................................................
BRAKES 2.25 Petrol and V8 Engine

System ..............................................................
Coil springs controlled by telescopic dampers front and

rear
Transverse location of axle by Panard rod, and fore and
aft location by two radius arms
Fore and aft movement inhibited by two tubular trailing
links. Lateral location of axle by a centrally positioned A
bracket bolted at the apex to a ball joint mounting. An
optional levelling unit is positioned between the ball joint
and upper cross member
Direct acting servo assisted dual braking system with

Girling tandem master cylinder and pressure differential
warning actuator, combination valve, o r G. valve
Footbrake -All Models

Front .............................................................
. Disc diameter ...............................................
Number of pistons per wheel ............................
Total lining area ............................................
Lining material.. ............................................
Rear ..............................................................
Drum diameter .............................................
Total lining area ............................................
Brake drum width.. ........................................
Lining material.. ............................................
Lockheed Disc
300 mm (11.81 in)
4
232 cm2
Don 230
Girling single cylinder drum brake
280 mm (11 in)
493 cm2
63.9
Ferodo 2629
Handbrake -All Models

Type ..............................................................
Drum diameter ................................................
Lining material.. ...............................................
Transmission drum brake cable operated

254 mm (10 in)
Don 269
BRAKES -2.25 and 2.5 litre Diesel engine

System ..............................................................
104I
Direct acting servo assisted dual braking system with

Girling tandem master cylinder and pressure differential
warning actuator, combination valve, or G . valve.
Servo assistance initiated by an engine driven air
evacuation pump and sustained by a vacuum tank
(vacuum tank deleted on 2.5)
Evacuation pump -2.25 litre Diesel

Maximum speed ...............................................
Oil capacity .....................................................
5000 rpm. Belt drive

40 cm3 (2.4 in3) SAE 15W-50
Evacuation pump -2.5 litre Diesel

Maximum speed ...............................................
Lubrication .....................................................
.Minimum vacuum !eve! at 2500 !pn ......................
4000 pm. Gear drive from camshaft

Oil feed via skew gear
0,8 bar
15
(047
STEERING -All Models

Type:
Manual -Early Models only .................................
Manual.. ............................................................
Optional power assisted -Early Models.. .................
Optional power assisted -Later Models.. .................
Ratios:
Manual Burman straight ahead ...............................
Manual Gemmer .................................................
Power assisted straight ahead. .................................
Number of turns lock to lock:
Manual.. ............................................................
Power assisted .....................................................
Camber angle .....................................................
Castor angle .......................................................
Swivel pin inclination.. ..........................................
Front wheel toe-out -permanent 4-wheel drive .........
Turning circle between kerbs:
Right-hand drive ..............................................
Left-hand drive ................................................
Steering wheel diameter.. ......................................
Steering damper ..................................................
Track ................................................................
Steering column type ............................................
14,O m (45.67 ft)

13,28 m (43.58 ft)
420 mm (16.5 in)
Fitted to drag link
1485,90 mm (58.50 in)
Collapsible coupling
WHEELS AND TYRES -All Models

Type of wheel .....................................................
Wheel size. .........................................................
Number of studs ..................................................
Tyre size ............................................................
Ventilated disc
5.50 in F x 16 in
5
7.50 x 16
ELECTRICAL EQUIPMENT -All Models

System ..............................................................
12 volt, negative earth
Battery -2.25 litre Petrol and V8 engine

Type:
Lucas -standard 9 plate .................................
Chloride - standard 9 plate .............................
Lucas -cold climate 13 plate ...........................
Chloride -cold climate 13 plate .......................
B.B.M.S. No. 371

B.B.M.S. No. 291
B.B.M.S. No. 389
B.B.M.S. No. 369
Battery -2.25 and 2.5 Eitre Diesel engine

Type ..............................................................
16
Burman recirculating ball

Gemmer Hour-glass worm and wheel
Adwest Varamatic
Adwest Lightweight or Gemmer
20,55: 1
20,2: Constant
17.5:l
4.75
3.49
Zero
3"
7"
1,19 - 2,38 mm (A
in)
Designation
190/84/90
Designation
315/120/92
Chloride B.B.M.S. No. 243 15 plate

designation 395/175/90
(?:
. ,
--s
GENERAL SPECIFICATAION DATA

,
.,..:.-,.:.;:
..
":. ?: ,:I
.- ,,,.
,!Z', .
I.
Alternator - 2.25 litre Petrol and Diesel and 2.5 Diesel

Type ..............................................................
Maximum D.C. output at 6000 rpm .......................
Rotor -winding resistance .................................
Stator -winding resistance per phase ...................
New brush length ..............................................
Renew brush at ................................................
Brush spring pressure ........................................
Regulator controlled voltage ...............................
1041
Lucas A115-34
34 amps
3.27 ohms at 20C f 5%
0.138 ohms at 20C f 5 %
20 mm
10 mm
1.3 - 2.7 N (4.7 - 9.8 oz)
13.6 - 14.4 volts measured across battery
Note: From the following engine numbers a 45 amp output alternator is fitted.
12505497C
llH05639C
llH05629C
..
Land Rover 90/110 2.5 litre Diesel

Land Rover 90 2.3 litre Petrol
Land Rover 110 2.3 litre Petrol
Alternator -V8 engine

Type ..............................................................
Maximum D.C. output at 6000 rpm .......................
Rotor -winding resistance.. ...............................
Stator -winding resistance per phase ...................
New brush length. .............................................
Renew brush at ................................................
Brush spring prcssure ........................................
Regulator controlled voltage ...............................
Lucas A115-45
45 amps
3.2 ohms at 20C f 5%
0.092 ohms at 20C f 5%
20 mm
10 mm
1.3 - 2.7 N (4.7 - 9.8 OZ)
13.6 - 14.4 volts measured across battery
Starter motor -2.25 Petrol engine

Type ..............................................................
Brush spring tension ..........................................
Minimum brush length .......................................
Lucas 2M100
1020 gms (36 02s)
9,s mm (0.375 in)
Starter motor -2.25 and 2.5 Diesel engine

Type ..............................................................
New brush length ..............................................
Renew brush at ................................................
Armature end-float Cast aluminium intermediate bracket .................
Pressed steel intermediate bracket .....................
Commutator minimum diameter ..........................
0,03 - 1,4 mm (0.001 - 0.056 in)

0,03 - 1,55 mm (0.001 - 0.061 in)
38 mm (1.5 in)
Starter motor -VS engine

Type ..............................................................
Brush spring tension ..........................................
Brush minimum length .......................................
Lucas 3M100 pre-engaged

1020 gms (36 ozs)
9,5 mm (0.375 ins)
Lucas 2M113
22.2 mm (0.875 in)
8 mm (0.312 in)
17
04
Wiper motor -All Models

Type ..............................................................
Armature end-float ...........................................
Minimum brush length.. .....................................
Lucas 14W uprated two-speed

0 , l - 0,20 mm (0.004 - 0.008 in)
4,8 mm (0.190 in)
Distributor - All Petrol engines ..............................
Coil -All Petrol engines .......................................
Fuses AI1 Models

Type ..............................................................
Starter motor -2.5 litre Diesel -Later Models

Type ..............................................................
18
12 cartridge fuses of the following values:

Three 10 amp
Six 8 amp
One 12 amp
Two 2.5 amp
Paris Rhone D9R91 12 volt
04
L
TYRE PRESSURES
Tyres -size and type
6.00-16
CROSS-PLY
7.50-16
CROSS-PLY
205R16
RADIAL-PLY
7.50R16
RADIAL-PLY
7.50-16
CROSS-PLY
750R16
RADIAL-PLY
bar
Ibf/in2
kgf/cm2
bar
Ibf/in2
kgf/cm2
bar
Ibflin2
kgf/cm2
bar
lbf/inZ
kgf/cm2
bar
Ibf/in*
kgf/cm2
bar
Ibf/in2
kgf/cm2
Normal
All load conditions
Rear
Front
2.4
3,25
35
47
2.5
393
19
2,4
28
35
2,o
2.5
19
2,4
28
35
2,O
295
19
2,75
28
40
23-3
2,8
19
2,9
28
42
28
3,O
19
373
28
48
2.0
3.4
Emergency soft
Unladen
Front
1s
16
1,1
1,1
16
131
191
16
1,1
191
16
1,1
1,1
16
'1J
191
16
1.1
Laden
Rear
1,1
16
1J
1,1
16
1.1
1s
16
1,1
171
16
1s
1.1
16
1s
171
16
1J
Front
171
16
1J
1J
16
1.1
1J
16
191
171
16
1.1
191
16
1,1
1s
16
1,1
Rear
1.6
23
1.6
1,6
23
1.6
125
23
1.6
1,6
23
1,6
1.8
26
1.8
1,8
26
1,8
REPLACEMENT BULBS AND UNITS

.......
.; ...
..
........
'L..
..,.
Headlamps:
-UK and Europe (except France) .......................
- France and Algeria ........................................
- Restof world, right-hand steering .....................
-Rest of world, left-hand steering .......................
Front side lamps ..................................................
Side repeater lamps ..............................................
Stopltail lamps ....................................................
Flasher lamps. .....................................................
Number plate lamp ..............................................
Reverse lamp ......................................................
Rear fog guard lamp .............................................
Interior lamp ......................................................
Warning lights .....................................................
Instrument illumination. ........................................
Hazard switch warning light ...................................
60155 W Halogen bulb

60155 W Halogen bulb, yellow
75150 W Sealed beam unit
60150 W Sealed beam unit
1 2 v 5w
12v4 w
1 2 v 2115w
1 2 v 21w
12v4 w
1 2 v2 1 w
1 2 v 21w
1 2 v 21w
12v 12w
1 2 v 3w
12V 0.6W
19
1041

VEHICLE WEIGHTS AND PAYLOAD
Payload figures quoted in the accompanying table are nominal values for a base specification vehicle and will in
general represent the maximum, as any options or extras fitted to the vehicle will increase its unladen weight and
hence decrease its allowable payload.
When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the unladen vehicle
weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values.
It is the customers responsibility to limit the vehicles payload in an appropriate manner such that neither maximum
axle loads nor Gross Vehicle Weight are exceeded.
Land Rover Ninety
Model
-PetroVDiesel
Gross Vehicle Weight
2.5P
Soft Top
2.5D
3.5P
23
Pick-up
2.5D
3.5P
2.5P
1635
765
1516
884
1672
728
1548
852
1631
769
1512
888
1648
Hard Top
2.5D
Station Wagon
2.5D
3.5P
3.5P
2.5P
1644
7Sb
1525
875
1690
710
1571
829
1727
673
1603
797
1686
714
1567
833
1671
879
1522
998
1717
833
1598
952
1754
796
1630
920
1713
837
1594
956
STANDARD SUSPENSION 2400 kg
EEC Kerb Weight
kg
EEC Payload
kg
Unladen Weight
kg
kg
Payload
1606
794
1487
913
1643
757
1519
1602
798
1483
917
881
752
1529
871
1685
715
I561
839
Maximum Axle Weights, all Ninety models with Standard Suspension

EEC Kerb Weight
EEC Payload
Untaden Weight
Payload
Front Axle 1200 kg

HIGH L O A D SUSPENSION 2550 kg
1629
1662
kg
1633
1670
880
921
888
kg
917
1543
1546
1510
kg
1514
kg
1004
1036
1040
1007
Rear Axle 1380 kg
1699
851
1575
975
1658
892
1539
1011
1675
875
1556
Y)4
1712
838
1588
962
Maximum Axle Weights, all Ninety models with High Load Suspension
Front Axle 1200 kg
Rear Axle 1500 kg
Land Rover One Ten

~~
Model - PelroUDiesel

EEC Kerb Weight
EEC Payload
Unladen Weight
Payload
Soft Top
2.5P 2.5D 3.5P
2.5P
UNLEVELLED SUSPENSION 3050 kg
kg
kg
kg
kg
1723
1327
1588
1462
1742
1308
1599
1451
1698
1352
1563
1487
1724
1326
1589
1461
Pick-up
2.5D
1743
1307
1600
1450
3.5P
Hard Top
2.5P
2.5D
3.5P
Station Wagon
2.5P
2.5D
3.51
High Capacity Pick-up

2.5P
2.5D
3.5P
1699
1351
1564
1486
1777
1273
1642
1408
1887
1163
1752
1906
1298
1287
1862
1188
1727
1323
1813
1237
I678
1372
1859
1191
1716
1334
1778
1272
1643
1407
1872
1078
1737
1213
1823
1127
1869
1688
1726
1224
1788
1162
16.53
1297
1796
1254
1653
1397
1752
1298
1617
1433
1144
1763
Maximum Axle Weights, a11 One Ten models with Unlevelled Suspension
Front Axle 1200 kg
Rear Axle 1850 kg
Gross Vehicle Wcight
1.EVELLED SUSPENSION 2950 kg
EEC Kerb Weight

EEC Payload
kg
kg
Unladen Weight
kg
Payload
kg
1733
1217
1598
1352
1752
1198
1609
1341
1708
1242
1573
1377
1734
1216
1599
1351
1753
1197
1610
1340
1709
1241
1574
1376
1787
1806
1163
1144
1652
1298
1663
1287
1762
1188
1627
1323
1897
1053
1762
1188
I916
1034
1773
1177
1262
1081
Maximum Axle Weights. all One Ten models with Levelled Suspension
Front Axle 1200 kg
Rear Axle 1750 kg
e-<\/
20
ENGINE TUNING DATA
105I
V8 PETROL ENGINE TUNING DATA

(with 4-speed gearbox and without electronic ignition)
..... 1
.I.
,'
..
ENGINE
Firing order ........................................................
Cylinder numbering system, front to rear:
Left bank ........................................................
Right bank ......................................................
Compression pressure (minimum) ...........................
Timing marks. .....................................................
Valve clearance.. .................................................
Valve timing:
Inlet opens ......................................................
Inlet closes ......................................................
Inlet duration.. .................................................
Inlet peak .......................................................
Exhaust opens.. ................................................
Exhaust closes.. ................................................
Exhaust duration ..............................................
Exhaust peak ...................................................
9.35:l or 8.13:l Dependent upon market

1--&-4-=5-7-2
1357
8-2
9,5 kgf cm2 (135 lbf in')
On crankshaft pulley vibration damper
Not adjustable
36" B.T.D.C.
64" A.B.D.C.
280"
99" A.T.D.C.
74" B.B.D.C.
26" A.T.D.C.
280"
119" B.T.D.C.
CARBURETTERS
Type .................................................................
European Australian .........................................
Other markets -non-emission ............................
Needle:
Australian .......................................................
-emission ..................................
Idle speed (engine hot):
Australian .......................................................
-emission..................................
Fast idle speed (engine hot) ....................................
Mixture setting -CO at idle:
Australian .......................................................
Other markets ..................................................
2% - 3.5% Pulsair connected

1.WO
- 3% Pulsair connected
IGNITION
Coil makehype ....................................................
Primary resistance at 20C (68F) .............................
Consumption, ignition on, at 2000 rpm .....................
Sparking plug type ...............................................
Sparking plug gap ................................................
Ignition timing, dynamic or static.. ...........................
Fuel octane rating Australia.. .................................
Non-emission .............................
Emission ...................................
Engine idle speed.. ...............................................
A C Delco with ballast resistor

1.2 - 1.4 ohms
1amp
Champion N12Y or Unipart GSP131
0,71 - 0,84 mm (0.028 - 0.033 in)
5" to 7"B.T.D.C.
97 RON minimum
97 RON minimum
90 RON minimum
750 rpm maximum with vacuum pipe disconnected
Two Solex
175 CDSE
175 CD3
BIFH
BIFQ
BIFK
700 - 750 rpm (run-in) 550 - 650 rpm (new engine)

550 - 650 rpm
700 - 750 rpm (run-in) 550 - 650 rpm (new engine)
1050 - 1150 rpm
05
ENGINE TUNING DATA
DISTRIBUTOR
Makehype. .........................................................
Rotation of rotor .................................................
Dwell angle ........................................................
Contact breaker gap .............................................
Condenser capacity ..............................................
Centrifugal advance range and capsule.. ....................
Vacuum advance capsule range ...............................
Vacuum retard capsule range.. ................................
Lucas 35D8
Anti-clockwise
26" - 28"
0,35 - 0,40 mm (0.014 - 0.016 in)
0.18 - 0.25 microfarad
2" - 4" at 750 rpm
1"-3" at 800 rpm
12"-14"at2300rpm 15.03 7"-9"at 1800rpm
1/20 - 4%" at 10 in Hg
Emission 2%" - 4W at 10 in Hg
5" -Tat 20 in Hg
Engines 7" - 9" at 20 in Hg
5"- 7" at 9 in Hg
5"- 7" at 9 in Hg
5" - 7" at 14 in Hg
5"- 7" at 14in Hg
ADR
36
Emission
Engines
V8 ENGINE TUNING DATA

(Ninety and One Ten V8 with 5-speed gearbox and electronic ignition)
EUROPE
ENGINE
Valve timing
Opens ............................................................
Closes ............................................................
Duration .........................................................
Valve peak ......................................................
CARBURETTERS
Type .................................................................
Solex specification number.. ...................................
Needle ..............................................................
Idle speed (engine hot).. ........................................
Mixture setting- CO at idle ..................................
IGNITION
Distributor makehype.. .........................................
Direction of rotation.. ............................. ..:...........

Centrifugal advance
Decelerating check with vacuum retard pipe
disconnected
Engine rev/min
3600. ..............................................................
2400. ..............................................................
1600...............................................................
1000...............................................................
No advance below 500 rev/min
Ignition timing, dynamic;
models with emission control ...............................
V8 cylinder
8.13:l
Inlet
30" B .T.D. C.
75" A.B. D. C.
285"
112.5" A.T.D.C.
Exhaust
68" B.B.D.C.
37" A.T.D.C.
285"
105.5" B.T.D.C.
2 x Solex 175 CDSE

3994
BIFK
700 to 750 revlmin (run-in engine)
550 to 650 rev/min (new engine)
1050 to 1150 rev/min
1.5 to 3% Pulsair connected
Lucas 35 DM8 Electronic (Early Models)

Lucas 35 DLM8 Electronic (Later Models)
Clockwise
Crankshaft angle
22" to 28"
13" to 21"
5" to 9"
0" to 3"
6" B.T.D.C. with vacuum pipes disconnected using 90-93

octane fuel - 2star rating in UK
ENGINE TUNING DATA
05
L

,::7.
,,
<,.;,:
'."
. .+.:
.....
'
AUSTRALIA
ENGINE
Valve timing
Opens ............................................................
Closes ............................................................
Duration .........................................................
Valve peak ......................................................
. . .
CARBURETTERS
Type .................................................................
Needle ..............................................................

Mixture setting - CO at idle ..................................
IGNITION
Direction of rotation. ............................................

Centrifugal advance
disconnected
Engine rev/min
2900.. .............................................................
2400. ..............................................................
1600...............................................................
Ignition timing ....................................................
V8 cylinder
9.35: 1
Inlet
30" B.T.D.C.
75" A.B .D. C.
285"
112.5"A.T.D.C.
Exhaust
68" B.B.D.C.
37" A.T.D.C.
285"
105.5"B.T.D.C.
2 x Solex 175 CDSE

4104
BIFH
700 to 750 rev/min (run-in engine)
2% to 3.5% Pulsair connected

Clockwise
Crankshaft angle
12" to 16"
8" to 12"
2" to 6"
6" B.T.D.C. with vacuum pipes disconnected using 96

octane fuel

SAUDI ARABIA
ENGINE
Valve timing (low lift camshaft)
Opens ............................................................
Closes ............................................................
Duratien .........................................................
Valve peak ......................................................
V8 cylinder
8.13: 1
Inlet
36" B.T.D.C.
64" A.B .D. C.
280"
99" A.T.D.C.
Exhaust
74" B.B.D.C.
26" A.T.D.C.
*-\on0
LDV
119"B.T.D.C.
05
ENGINE TUNING DATA
CARBURETTERS
Type .................................................................
Needle ..............................................................

Mixture setting - COat idle ..................................
IGNITION
Direction of rotation.. ...........................................

Centrifugal advance
disconnected
Engine rev/min
4600. ..............................................................
3600. ..............................................................
3000.. .............................................................
2400., .............................................................
1600.. .............................................................
Ignition timing, dynamic;
models with emission control ...............................
2 x Solex 175 CDSE

3999
BIFC
1.5% to 3% Pulsair connected

Clockwise
Crankshaft angle
21" to 25"
16" to 20"
12" to 16"
7" to 11"
1" to 3"
6" B.T.D.C. with vacuum pipes disconnected using 90-93

octane fuel

ALL COUNTRIES EXCEPT EUROPE, SAUDI ARABIA AND AUSTRALIA

ENGINE
Compression ratio,. ..............................................
Valve timing (low lift camshaft)
Opens ............................................................
Closes ............................................................
Duration .........................................................
Valve peak ......................................................
CARBURETTERS
Type .................................................................
Needle ..............................................................
V8 cylinder
8.13:1
Inlet
36" B.T.D. C.
64" A.B.D.C.
280"
99" A.T.D.C.
Exhaust
74" B.B.D.C.
26" A.T.D.C.
280"
119" B.T.D.C.
2 x Solex 175 CDSE

4000
BIFQ
ENGINE TUNING DATA

SPARKING PLUGS
8.0:l compression ratio .........................................
Gap ..................................................................
Champion N12Y or Unipart GSP 131

0,75-0,80mm (0.029-0.032in)
IGNITION COIL
Makehype.. ........................................................
Consumption -ignition on at engine idle speed .........
AC Delco 7992188
3.0 - 3.5 ohms
2.0 amps approx.
CARBURETTER
Makeltype.. ........................................................
Weber 32/34 DMTL
Venturi .............................................................
Auxiliary Venturi ................................................
Main jet .............................................................
Air correction jet .................................................
Emulsion tube.. ...................................................
Idle jet ..............................................................
Idle CO% ..........................................................
Idle speed -hot.. ................................................
Primary
24
4
110
160
30
55
Secondary
25
4
115
160
F30
60
1%- 2.5%
600 - 700 rpm
2.5 LITRE PETROL ENGINE TUNING DATA
ENGINE
Firing order ........................................................
Compression pressure (approximately): ....................
Ignition timing dynamic @ 2000 rpm ........................
Static, if no dynamic equipment available ..................
Timing marks. .....................................................
Valve clearance, inlet and exhaust ...........................
Valve timing:
Inlet opens ......................................................
Inlet closes ......................................................
Inlet peak .......................................................
Exhaust opens.. ................................................
Exhaust closes.. ................................................
Exhaust peak ...................................................
DISTRIBUTOR -LUCAS
Type .................................................................
Rotation of rotor .................................................
Contact breaker gap .............................................
Dwell angle ........................................................
Centrifugal advance range .....................................
.,
vacuum advance capsuie range ...............................
1-3-4-2
11,2 kgf cm2 (160 Ibf in2) @ 300 rpm cranking speed
with vacuum pipe
16" B.T.D.C. using 90 octane fuel
T.D.C.
disconnected
On crankshaft pulley
0,25 mm (0.010 in) Engine hot
11" B.T.D.C.
47"A.B.D.C.
108" A.T.D.C.
46" B.B.D.C.
18" A.T.D.C.
104" B.T.D.C.
U_..
With a 0,38 mm (0.015 in)

valve clearance.
Nominal setting for
checking only.
Lucas 45D4
Anti-clockwise
0,35 - 0,40 mm (0.014 - 0.016 in)
49" - 59"
0" - 1" at 500 Distributor rpm
18" - 20" at 2250 Distributor rpm
0" - M"at 3.5 Hg
11" - 13" at 25 Hg
'1.
c':J
ENGINE TUNING DATA
..
.. ?:.,' .
-,
,..*-.I.
..is,::::i:/
.".
:%;'...~
-.:
......::
:.
SPARKING PLUGS
8.0:1 compression ratio .........................................

Gap ..................................................................
Champion N9YC
0,72 - 0 3 8 mm (0.028 - 0.035 in)
IGNITION COIL
Makehype ..........................................................
Consumption -ignition on at engine idle speed .........
Bosch 0221 119 368

2.9 ohms
2.0 amps approx.
CARBURETTER
Makehype. .........................................................
Needle valve.. .....................................................
Weber 32/34 DMTL

175
Venturi .............................................................
Auxiliary Venturi ................................................
Main jet .............................................................
Air correction jet .................................................
Emulsion tube.. ...................................................
Idle jet ..............................................................
Idle CO% ..........................................................
Idle speed - hot -Non Air Conditioning.. ...............
Idle speed -hot -Air Conditioning.. .....................
Float level ..........................................................
Primary
24
4
112
160
F30
52
1.5% k 1%
700 rpm
800 rpm k 50 rpm
7 k 0,5 mm (0.275 iz 0.019 in)
105I
Secondary
25
4
112
190
F39
60
2.25 and 2.5 LITRE DIESEL ENGINE TUNING DATA
ENGINE
Firing order ........................................................
. .
Injection timing.. .................................................
Timing marks:
Valve timing ....................................................
Injection timing. ...............................................
Valve clearance inlet and exhaust .........................
Valve timing:
Inlet opens ......................................................
Inlet closes ......................................................
Inlet peak .......................................................
Exhaust opens.. ................................................
Exhaust closes.. ................................................
Exhaust peak ...................................................
Low idle speed .................................................
High idle speed ................................................
16" B.T.D.C.
42" A.B.D.C.
103" A.T.D.C.
5l"B.B.D.C.
13" A.T.D.C.
109" B.T.D.C.
650 5 20 rpm
4200 +- 20 rpm
INJECTORS
Makehype.. ........................................................
Nozzle size .........................................................
Opening pressure.. ...............................................
CAV Pintaux
BDNO/SPC 6209 or BDNO/SP 6209
135 Atm
1-3--4---2
13" B.T.D.C. (2.25 litre Diesel)
On engine flywheel and damper on 2.5 Diesel
On engine flywheel and pump flange
0,25 mm (0.010 in)
...
. . .......,
.
. :.
~
,.
ENGINE TUNING DATA

HEATER PLUGS
Makeltype ..........................................................
DISTRIBUTOR PUMP
Makehype. .........................................................
Direction of rotation.. ...........................................

Maximum speed setting (sealed) 2.25 engine ..............
Maximum speed setting (sealed) 2.50 engine ..............
Back leakage rate 150 - 100 Atm:
New nozzle ......................................................
Original nozzle.. ...............................................
Probe type, Champion CH 63 12 volt
CAV DPA-2.25 DPS-2.50 type with mechanical governor

and auto advance and solenoid electrical shut-off
Clockwise, viewed from drive end
4200 engine rpm
4400 k 8 rpm
7 seconds
5 seconds
. ..
fi.........
':I
.....
.1.
TORQUE WRENCH SETTINGS
ENGINE .
2.25 litre Petrol and Diesel
Bearing in water pump casing .................................
Breather filter to top cover .....................................
By-pass housing to thermostat housing ......................
Carburetter to inlet manifold ..................................
Chainwheel pulley to camshaft ................................
Clutch cover plate to flywheel .................................
Connecting rod to cap ...........................................
Fan assembly to water pump hub .............................
Fly wheel to crankshaft .........................................
Fuel pump to side cover .........................................
Heat shield bracket to manifold ...............................
Heat shield to bracket ...........................................
Oil strainer to mounting bracket ..............................
P . clip to lifting bracket .........................................
Plug to immersion heater tapping ............................
Oil pump cover to pump body .................................
Rocker shaft to pedestal ........................................
Solenoid heat shield to manifold heat shield ...............
Starter motor to housing ........................................
Sump plug to sump ...............................................
Distributor clamp ................................................
Distributor to adaptor ...........................................
Pulley to crankshaft ..............................................
Water temperature to cylinder head adaptor ..............
Spark plug ..........................................................
Adaptor for water temperature transmitter to
cylinder head ...................................................
Cover thermostat housing to cylinder head ................
Lifting bracket to cylinder head ...............................
Rocker pedestal to cylinder head .............................
Top cover to cylinder head .....................................
Alternator adjusting link to cylinder block .................
Alternator mounting bracket to cylinder block ............
Camshaft thrust plate to cylinder block .....................
Chain damper to cylinder block ...............................
Cylinder head (Diesel) to cylinder block ....................
Cylinder head (Petrol) to cylinder block ....................
DPA injector pump (Diesel) to cylinder block ............
Distributor housing (Petrol) to cylinder block .............
Drive shafdgear to cylinder block ............................
Engine mounting foot to cylinder block .....................
Flywheel housing to cylinder block ...........................
Front cover to cylinder block ..................................
Main bearing cap (Diesel) to cylinder block ...............
Main bearing cap (Petrol) to cylinder block ................
Oil feed pipe to cylinder block ................................
Oil filter to cylinder block ......................................
Oil pump to cylinder block .....................................
Plug oil gallery front to cylinder block .......................
Plug oil gallery rear to cylinder block ........................
Side cover to cylinder block ....................................
Side cover FP mounting to cylinder block ..................
Sump to cylinder block (bolts and nuts) .....................
Water pump to cylinder block .................................
Dipstick tube assembly to cylinder block ...................
Nm
7 .10
7 .10
22 .28
22 .28
40 .50
30 .38
37 .41
22 .28
130 .143
20 .28
22 .28
22 .28
22 .28
7 .10
20 .28
20 .28
20 .27
22 .28
40 .50
30 .40
13 .19
7 .10
260 .280
14 .18
14 .19
22 .28
7 .10
27 .40
22 .28
8 .11
22 .28
22 .28
7 .10
7 .10
115 .130
91 .113
22 .28
22 .28
10 .17
80 .95
40 .50
22 .28
130 .136
130 .136
20 .25
40 .50
22 .28
30 .40
30 .40
22 .28
22 .28
15 .20
22 .28
22 .28
Ibf ft
5 .7.3
5 .7.3
16 .20.6
16 .20.6
30 .36.8
22 .28
27 .30
16 .20.6
96 .105
14.7 .20.6
16 .20.6
16 .20.6
16 .20.6
5 .7.3
14.7 .20.6
14.7 .20.6
14.7 .20
16 .20.6
30 .36.8
22 .29.5
9.5 .14
5 .7.3
192 .206
10.3 .13.2
10.3 .14
16 .20.6
5 .7.3
20 .29.5
16 .20.6
6-8
16 .20.6
16 .20.6
5 .7.3
5 .7.3
84.8 .95.8
67 .83
16 .20.6
16 .20.6
7.4 .12.5
59 .70
30 .36.8
16 .20.6
96 .100
96 .100
14.7 .18.4
30 .36.8
16 .20.6
22 .30
22 .30
16 .20.6
16 .20.6
11 .14.7
16 .20.6
16 .20.6
1
06
ENGINE .
2.5 litre Diesel
DPS pump studs to front cover ................................
DPS pump to front cover .......................................
DPS pump to support bracket .................................
Pulley to DPS pump .............................................
Distributor pipe banjo bolts ...................................
Tensioner assembly ..............................................
Vacuum pump ....................................................
Oil squirt to cylinder block .....................................
Throttle linkage to DPS pump ................................
Throttle bracket to DPS pump ................................
Front cover to cylinder block ..................................
Front cover plate to cylinder block ...........................
Cover plate to front cover plate ...............................
Cowl mounting.bracket to front cover .......................
Timing pointer to front cover .................................
Drain plate to front cover .... .................................
ENGINE .
VS Petrol engine
Air intake adaptor to carbs ... .................................
Alternator mounting bracket o cylinder head ............
Alternator to mounting bracket ...............................
Alternator to adjusting link ....................................
Chainwheel to camshaft ........................................
Connecting rod bolt ..............................................
Clutch attachment to flywheel .................................
Cylinder head:
Outer row .......................................................
Centre row ......................................................
Inner row ........................................................
Distributor clamp bolt ...........................................
Exhaust manifold to cylinder heads ..........................
Fan attachment ...................................................
Flywheel to crankshaft ..........................................
Inlet 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 cap ...............................................
Oil sump drain plug ..............................................
Oil sump to cylinder block .....................................
Oil sump rear to cylinder block ...............................
Rocker cover to cylinder head .................................
Rocker shaft bracket to cylinder head .......................
Spark plug ..........................................................
Starter motor attachment .......................................
Damper to crankshaft ...........................................
Timing cover to cylinder block ................................
Tempatrol unit to water pump ................................
Water pump pulley to water pump hub .....................
X$Im+
v
---..__
aLGi
puiiip
---.-- *IU- c;yllIlUCl

--.l:-A--.LUlOLK
L I I I I I I I ~LUVCI
-.I
................
CLUTCH .
V8 Petrol engine
Clutch cover bolts ................................................
Slave cylinder bolts ..............................................
Nm
6-10
22 .28
22 .28
42 .48
14 .20
22 .28
22 .28
14 .20
5-7
5-7
22 .28
22 .28
22 .28
22 .28
22 .28
7 - 10
lbf ft
4.5 .7.3
16 .20.6
16 .20.6
31 .35.4
10.3 .15
16 .20.6
16 .20.6
10.3 .15
4-5
4-5
16 .20.6
16 .20.6
16 .20.6
16 .20.6
16 .20.6
5 .7.3
24
34
24
24
54 .61
47 .54
24 .30
17
25
17
17
40 .45
35 .40
18 .22
54 .61
88 .95
88 .95
19 .22
19 .22
11,5
74 .81
47 .54
24
68 .75
88 .95
13,5 .20
11 .14
25 .30
40
40,6 .47
8-11
17,6 .20.3
7
34 .40
13,8 .16.2
40,6 .47,4
257 .285
24 .30
36 .40
23
24 .30
40 .45
65 .70
65 .70
1 4 - 16
14- 16
9
55 .60
35 .40
17
50 .55
65 .70
10 .15
8.10
18 .22
30
30 .35
5-8
13 .15
5
25 .30
10- 12
30 .35
190 .210
18 .22
27 .30
17
18 .22
Nm
27. 5
27. 5
lbf ft
20
20
.......
....
'U .....
C'
...r;
; ..' \
. :':.
.
..
. .
'
....
.
.I.
.....
.
...
. ... .
..'
CLUTCH -4-cylinder Petrol and Diesel engine

Clutch cover bolts ................................................
Nm
30 .38
Ibf ft
22 .28
MAIN GEARBOX (FIVE-SPEED) LT 77 mm .

4-cylinder Petrol and Diesel engine
Oil pump body to extension case .............................
Clip to clutch release lever .....................................
Attachment plate to gearcase ..................................
Attachment plate to remote housing .........................
Extension case to gearcase .....................................
Pivot plate ..........................................................
Remote selector housing to extension case .................
Gear lever housing to remote housing .......................
Guide clutch release sleeve ....................................
Slave cylinder to clutch housing ...............................
Front cover to gearcase .........................................
5th support bracket ..............................................
Plunger housing to remote housing ..........................
Blanking plug extension case ..................................
Gear lever retainer ...............................................
Yoke to selector shaft ...........................................
Fixing gear lever assembly nut ................................
Reverse pin to centre plate nut ................................
Clutch housing to gearbox bolt. ...............................
Plug -detent spring ............................................
Oil drain plug .......................................................
Oil filter plug ......................................................
Plug oil filler -remote housing ..............................
Breather ............................................................
Oil level plug ......................................................
Blanking plug -reverse switch hole ........................
Fifth gear layshaft nut ...........................................
7 .10
7 - 10
7 - 10
7 .10
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
7 - 10
7 - 10
22 .28
40 .47
47 .54
65 .80
22 .28
25 .35
25 .35
25 .35
7 - 11
25 .35
20 .27
204 .231
5-7
5-7
5-7
5-7
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
5 -7
5-7
16 .21
30 .35
35 .40
48 .59
16 .21
19 .26
19 .26
19 .26
5-8
19 .26
15 .20
130 .170
MAIN GEARBOX (FIVE-SPEED) LT85 .

V8 engine
Stop .
4th speed adjustment ..................................
Clip to clutch releasc lever .....................................
Spring housing to top cover ....................................
Plate .
lower (retained with Loctite 270) ..................
Slave cylinder t o clutch housing ...............................
5th fork bracket ...................................................
Front cover to bearing plate ...................................
Plate -Lower (upper fixings) ................................
Selector fork to shaft and reverse beam to shaft ...........
Top cover to gearbox ............................................
lst/2nd selector fork to shaft ...................................
Extension case to gearbox ......................................
Extension case to gearbox ......................................
Extension case t o gearbox ......................................
Extension case t o gearbox ......................................
Clutch housinghearing plate/gearbox .......................
Layshaft ............................................................
Reverse lever pivot ..............................................
Gross hole/gearbox casing ......................................
Filler/top cover ....................................................
Oil leveygear case ................................................
Filter plug ..........................................................
Drain plug ..........................................................
Reverse light switch hole-blanking plug .....................
Switch reverse light (optional) ................................
7 - 10
7 - 10
7 - 10
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
30 .40
47 .54
47 .54
47 .54
47 .54
65 .80
204 .231
65 .80
13,5 .20
25 .35
25 .35
65 .80
25 .35
1 3 3 .20
13,5 .20
5-7
5-7
5-7
16- 21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
22 .30
35 .40
35 .40
35 .40
35 .40
48 .59
150 .170
48 .59
I0 .15
19 .26
19 .26
48 .59
19 .26
10- 15
10- 15
3
1061
TRANSFER BOX LT230R .

4-cylinder Petrol and Diesel engine
Pinch bolt, operating arm ......................................
Gate plate to grommet plate ...................................
End cover ..........................................................
Speedometer cable retainer ....................................
Speedometer housinghear output ............................
Locating plate to gear change housing .......................
Bottom cover t o transfer case .................................
Front output housing to transfer case ........................
Cross shaft housing to front output housing ................
Gear change housing ............................................
Pivot shaft ..........................................................
Connecting rod ...................................................
Retaining plate intermediate shaft ...........................
Front output housing cover ....................................
Gear change housing ............................................
Bracket to extension housing ..................................
Finger housing to front output housing ......................
Mainshaft bearing housing .....................................
Brake drum ...............................
Gearbox to transfer box ........................................
Bearing housing to transfer gearbox .........................
Speedometer housing to transfer gearbox ..................
Selector fork to cross shaft .....................................
Yoke to selector shaft high/low ...............................
Selector fork high/low to shaft .................................
Operating arm high/low .........................................
Transmission brake ..............................................
Gearbox to transfer case ........................................
Oil drain plug ......................................................
Differential case ..................................................
Output flange .....................................................
Differential case rear and shaft main drive
214-wheel drive .................................................
Link arm and cross shaft lever to ball joint .................
Oil filler/level plug ...............................................
Transfer breather .................................................
Nm
7 - 10
7 - 10
7 - 10
7 - 10
See note
5-7
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
22 .28
40 .50
40 .50
40 .50
22 .28
22 .28
22 .28
22 .28
65 .80
40 .50
See note
25 .35
55 .64
146 .179
19 .26
40 .47
108 .132
66 .80
8 - 12
25 .35
7 - 11
50 .60
6-9
19 .26
5-8
Ibf ft
5-7
5-7
5-7
5-7
4-5
16 .21
16 .21
16 121
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
16 .21
29 .37
29 .37
29 .37
16 .21
16 .21
16 .21
16 .21
48 .59
29 .37
NOTE:- Studs to be assembled into casings with sufficient torque to wind them fully home. but this torque must not
exceed the maximum figure quoted for the associated nut on final assembly .
TRANSFER GEARBOX LT230T .
4 cylinder Petrol and Diesel engine and VS
Fixings securing mounting brackets to gearbox ...........
Pinch bolt operating arm .......................................
Gate plate to grommet plate ...................................
Bearing housing to transfer case ..............................
Speedometer cable retainer ....................................
speedometer housing ...........................................
Locating plate to gear change .................................
Bottom cover to transfer ........................................
Front output housing to transfer ..............................
Front output housing to transfer ..............................
80 .100
7 - 10
7 - 10
7 - 10
7 - 10
See note
5-7
22 .28
22 .28
22 .28
59 .73
5-7
5-7
5-7
5-7
4-5
16 .21
16 .21
16 .21
TRANSFER GEARBOX LT230T 4 cylinder Petrol and Diesel engine and V8 (cont.)
Cross shaft housing to front output housing ................
Gcar change .......................................................
Gear change ........................................................
Cross shaft to highAow lever ...................................
Pivot shaft to link arm ...........................................
Connecting rod ...................................................
Anti-rotation plate intermediate shaft .......................
Front output housing cover ....................................
Pivot bracket to extension housing ...........................
Finger housing to front output housing ......................
Mainshaft bearing housing to transfer case .................
Brake drum to coupling flange ................................
Gearbox to transfer case
...............
End cover bearing housing to transfer case .................
Speedometer housing to transfer .............................
Speedometer housing to transfer .............................
Selector finger to cross shaft (highhow) .....................
Selector fork high/low to shaft .................................
Transmission brake to speedometer housing ..............
Transfer case assembly ..............
..............
Oil drain plug ......................................................
Detent plug ........................................................
Differential casings ..............................................

Front and rear out flange .......................................
Differential case rear ............................................
Oil filler and level plug transfer ...............................
Transfer breather .................................................
Inter shaft stake nut ..............................................
El
Nm
lbf ft
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
16 .21
22 .28
29 .37
40 .50
29 .37
40 .50
29 .37
40 .50
29 .37
40 .50
29 .37
40 .50
16 .21
22 .28
16 .21
22 .28
48 .59
65 .80
40 .50
29 .37
See note
19 .26
25 .35
Plug to be coated with Hylomar and peened .
Screw plug fully in (spring solid) then turn two
complete turns back .
40 .47
55 .64
108 .132
146 .179
50 .59
66 .80
19 .26
25 .35
7 - 11
5-8
96 .104
130 .140
NOTE:- Studs to be assembled into casings with sufficient torque to wind them fully home. but this torque must not
exceed the maximum figure quoted for the associated nut on final assembly .
GEARBOX AND TRANSFER BOX LT95 .

V8 Petrol engine
36,6 .44, 8
Bell housing to cylinder block bolts ..........................
1463 .179
Gearbox casing to bell housing 2 off .........................
85,
4 .104,4
Gearbox casing to bell housing 2 off .........................
85,4 .104,4
Gearbox casing to bell housing nuts ..........................
Gearbox casing to bcll housing stud and nuts .............. 146,5 .179
Output flange - rear-nut and bolts .......................
43,4 .5 1 3
Output shaft - rear-nut .....................................
146,5 .179
146,5 .179
Output shaft -front -nut ....................................
Gear selector spherical scat bolts .............................
13,6 .16,3
43,4 .51,5
Propeller shaft to flange bolts .................................
All other nuts and bolts:
9,9 .11,9
M6 ................................................................
M8 ................................................................
23:7 .29.7
M10 ...............................................................
48 .58
27 .33
108 .132
63 .77
63 .77
108 .132
32 .38
108 .132
108 .132
10- 12
32 .38
7.3 .8.7
17.5 .21.3
35.4 .42.8
I06I
FRONT AXLE
Hub driving member to hub ...................................
Brake disc to hub .................................................
Stub axle to swivel pin housing ................................
Brake caliper to swivel pin housing ..........................
Upper swivel pin to swivel pin housing ......................
Lower swivel pin to swivel pin housing ......................
Oil seal retainer to swivel pin housing .......................
Swivel bearing housing to axle case ..........................
Pinion housing to axle case .....................................
Crown wheel to differential case ..............................
Differential bearing cap to pinion housing .................
U/J flange to prop shaft .........................................
Mudshield to swivel pin housing ..............................
Bevel pinion nut ..................................................
Nm
60-70
65 .80
60 .70
120 .150
60 .70
22 .28
7 - 10
65 .80
36 .46
55 .61
80 .100
41 -52
7 - 10
95 .163
Ibf ft
44 .52
48 .59
44-52
88 .111
44 .52
16 .21
5-7
48 .59
26 .34
40 .45
54 .74
30 .38
5-7
70 .120
REAR AXLE AND FINAL DRIVE

Crown wheel to differential case ..............................
Rear cover to axle case ..........................................
Ball joint mounting bracket to axle case ....................
U1J flange to prop shaft .........................................
Drum to hub .......................................................
Rear brake assembly and stub axle rear to axle case .....
Hub driving member to hub ...................................
150 .170
20 .27
125 .142
41 .52
15 .20
60 .70
60 .70
111 .125
15 .20
92 .105
30 .38
11.15
44-52
44 .52
PROPELLER SHAFTS
Coupling flange bolts ............................................
43 - 51
32 .38
176
64
47
32
64
130
47
35
24
47
60
18
130
30
55
REAR SUSPENSION
Bottom link to chassis nut ......................................
Bottom link to mounting rubber nuts ........................
Top link bracket to chassis nuts ...............................
Bump stop rubber bracket nuts ...............................
Shock absorber bracket to chassis nuts ......................
Shock absorber upper attachment to bracket ..............
Anti roll bar bush to chassis nuts ..............................
Upper link ball joint to axle castle nut .......................
Anti roll bar ball joint castle nut ..............................
Shock absorber lower attachment nuts ......................
STEERING AND FRONT SUSPENSION
Tie bar to mounting arm nut ...................................
Mounting arm to chassis nuts ..................................
Tie bar to steering box nuts ....................................
Panard rod to mounting arm nut ..............................
Panard rod to anchor bracket nut .............................
Panard rod mounting bracket to chassis bolts ..............
Drop arm to drag link castle nut ..............................
Steering damper to drag link nut ..............................
Drop arm to steering box nut ..................................
Radius arm to axle nuts .........................................
Steering box to chassis nuts ....................................
Radius arms to chassis nuts ....................................
Track rod ciamp boit nuts ......................................
Drag link clamp bolt nuts .......................................
Steering wheel retaining nut ...................................
Road wheel nuts ..................................................
Ball joint nuts .....................................................
Collapsible coupling nuts ......................................
6
82
24
176
40
75
81
176
81
176
176
115 .130
81
50
176
176
81
176
14
14
38
108
41
45
60
130
60
130
130
85 .96
60
37
130
130
60
130
10
10
28
80
30
33
...
t
k-
($??;
..

BRAKES
Brake disc to hub .................................................
Brake caliper to swivel housing ...............................
Brake pipe connections to:
P.D.W.A. valve ...............................................
Servo, primary port ...........................................
Servo. secondary port ........................................
Jump hose -female., ........................................
Wheel cylinders ................................................
..
I
..
...
65 .80
120 .150
48 .59
88 .111
9 - 11
9 .11
20 .24
11 .13,5
6. 8 .9. 5
7-8
7-8
15 .18
8-10
5-7
ELECTRICAL EQUIPMENT .
V8 engine
Alternator:
Shaft nut .........................................................
Through bolts ..................................................
Rectifier bolts ..................................................
Starter motor to engine bolts ..................................
Starter motor:
Through bolts ..................................................
Solenoid fixing stud nut ......................................
Solenoid upper terminal nut ................................
Reverse light switch ..............................................
27. 2 .4 7 3
4. 5 .6.2
3.4 .3. 96
40.6 .47. 4
20 .35
3.3 .4.6
2.5 .2.9
30 .35
10.8
6
4
20 .27
8.0
4.5
3.0
15 .20
Lucas 35 DM8 Electronic ignition distributor V8 engine

Pick up bearing plate support pillars .........................
Pickupbarrelnuts ...............................................
1.0 .1.2
1.1 -1.5
9-11
10 .12
27. 2 .47. 5
4.5 .6.2
3. 4 .3.96
15 .30
40 .50
20 .35
3.3 .4.6
2.5 .2.9
11-22
30 .36.8
10.8
6
4
2
10.8
8
21
4.5
3
1.5
8
6
16
ELECTRICAL EQUIPMENT .
4-cylinder Petrol
and Diesel engine
Alternator:
Shaft nut .........................................................
Through bolts ..................................................
Rectifier bolts ..................................................
Heater plugs -Diesel ..........................................
Starter motor to engine .........................................
Petrol models:
Starter through bolts ..........................................
Diesel models:
Solenoid to starter nuts ......................................
Solenoid outer terminal nuts ................................
Starter yoke terminal outer nut ............................
Starter through bolts ..........................................
Starter earth stud nut .........................................
Eccentric pivot pin locknut ..................................
El
GENERAL F I ~ I N G
INSTRUCTIONS
07

PRECAUTIONS AGAINST DAMAGE
1. Always fit covers to protect wings before

commencing work in engine compartment.
2. Cover seats and carpets, wear clean overalls and
wash hands or wear gloves before working inside
car.
3. Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if this
occurs. Use Polythene sheets in boot to protect
carpets.
4. Always use a recommended Service Tool, or a
satisfactory equivalent, where specified.
5. Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.
SAFETY PRECAUTIONS
1: Whenever possible use a ramp or pit when working

beneath vehicle, in preference to jacking. Chock
wheels as well as applying hand brake.
2. Never rely on a jack alone to support vehicle. Use
axle stands or blocks carefully placed at jacking
points to provide rigid location.
3 . Ensure that a suitable form of fire extinguisher is
conveniently located.
4. Check that any lifting equipment uscd has
adequate capacity and is fully serviceable.
5. Inspect power leads of any mains electrical
equipment for damage and check that it is properly
earthed.
6 . Disconnect earth (grounded) terminal of vehicle
battery.
7. Do not disconnect any pipes in air conditioning
refrigeration system, if fitted, unless trained and
instructed to do so. A refrigerant is used which can
cause blindness if allowed to contact eyes.
8. Ensure that adequate ventilation is provided when
volatile degreasing agents are being used.
WARNING: Fume extraction equipment must be in
operation when trachloride, methylene chloride,
chloroform or perchlorethylene are used for
cleaning purposes.
9. Do not apply heat in an attempt to free stiff nuts or

fittings; as well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake lines from stray heat.
10. Do not leave tools, equipment, spilt oil etc.,
around or on work area.
11. Wear protective overalls and use barrier creams
when necessary.
PREPARATION
1. Before removing a component, clean it and its
surrounding areas as thoroughly as possible.
2. Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3 . Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to prevent
loss of fluid and entry of dirt.
4. Close open ends of oilways, exposed by component
removal, with tapered hardwood plugs or readily
visible plastic plugs.
5. Immediately a component is removed, place it in a
suitable container; use a separate container for
each component and its associated parts.
6. Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7 . Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1. Observe scrupulous cleanliness when dismantling

components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
dangerous malfunction if trapped in these systems.
2. Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
0-rings used for sealing are correctly replaced or
renewed, if disturbed.
3. Mark mating parts to ensure that they are replaced
as dismantled. Whenever possible use marking ink,
which avoids possibilities of distortion or initiation
of cracks, liable if centre punch or scriber are used.
4. Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller bearing
components).
5. Wire labels on to all parts which are to be renewed,
and to parts requiring further inspection before
being passed for reassembly; place these parts in
separate containers from those containing parts for
rebuild.
6. Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.
1051
INSPECTION -GENERAL
1. Never inspect a component for wear or

dimensional check unless it is absolutely clean; a
slight smear of grease can conceal an incipient
failure.
2. When a component is to be checked dimensionally
against figures quoted for it, use correct equipment
(surface plates, micrometers, dial gauges, etc.) in
serviceable
condition.
Makeshift
checking
equipment can be dangerous.
3. Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension is
exactIy limit size, and is otherwise satisfactory.
4. Use Plastigauge 12 Type PG-1 for checking
bearing surface clearances; directions for its use,
and a scale giving bearing clearances in 0,0025 mm
(0.0001 in) steps are provided with it.
BALL AND ROLLER BEARINGS
NEVER REPLACE A BALL OR ROLLER

BEARING WITHOUT FIRST ENSURING T H A T
IT IS IN AS-NEW CONDITION.
1. Remove all traces of lubricant from bearing under
inspection by washing in petrol or a suitable
degreaser;
maintain
absolute
cleanliness
throughout operations.
2. Inspect visually for markings of any form on rolling
elements, raceways, outer surface of outer rings or
inner surface of inner rings. Reject any bearings
found to be marked, since any marking in these
areas indicates onset of wear.
3. Holding inner race between finger and thumb of
one hand, spin outer race and check that it revolves
absolutely smoothly. Repeat, holding outer race
and spinning inner race.
4. Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any check
or obstruction to rotation, and reject bearing if
action is not perfectly smooth.
5. Lubricate bearing generously with lubricant
appropriate to installation.
6 . Inspect shaft and bearing housing for
discolouration or other marking suggesting that
movement has taken place between bearing and
seatings. (This is particularly to be expected if
related markings were found in operation 2.) If
markings are found, use Loctite in installation of
replacement bearing.
7. Ensure that shaft and housing are clean and free
from burrs before fitting bearing.
8. If one bearing of a pair shows an imperfection it is
generally advisable to renew both bearings: an
exception could be made if the faulty bearing had
covered a low mileage, and it could be established
that damage was confined to it only.
9. When fitting bearing to shaft, apply force only to

inner ring of bearing, and only to outer ring when
fitting into housing.
U
\
ST1042M
10. In the case of grease-lubricated bearings (e.g. hub

bearings) fill space between bearing and outer seal
with recommended grade of grease before fitting
seal.
11. Always mark components of separable bearings
(e.g. taper roller bearings) in dismantling, to
ensure correct reassembly. Never fit new rollers in
a used cup.
- _
I
f a
+--*
OIL SEALS
1. Always fit new oil seals when rebuilding an

assembly. It is not physically possible to replace a
seal exactly when it has bedded down.
2. Carefully examine seal before fitting to ensure that
it is clean and undamaged.
3. Smear sealing lips with clean grease; pack dust
excluder seals with grease, and heavily grease
duplex seals in cavity between sealing lips.
4. Ensure that seal spring, if provided, is correctly
fitted.
5. Place lip of seal towards fluid t o be sealed and slide
into position on shaft, using fitting sleeve when
possible to protect sealing lip from damage by
sharp corners, threads or splines. If fitting sleeve is
not available, use plastic tube or adhesive tape to
prevent damage to sealing lip.
ST 1 038M
WLJ
&*:
%L;

-=
9
. I
>.
6 . Grease outside diameter of seal, place square to

housing recess and press into position, using great
care and if possible a bell piece to ensure that seal
is not tilted. (In some cases it may be preferable to
fit seal to housing before fitting to shaft.) Never let
weight of unsupported shaft rest in seal.
ST1037M
7. If correct service tool is not available, use a suitable

drift approximately 0,4 mm (0.015 in) smaller than
outside diameter of seal. Use a hammer VERY
GENTLY on drift if a press is not suitable.
8. Press or drift seal in to depth of housing if housing
is shouldered, or flush with face of housing where
no shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.
NOTE: Most cases of failure or leakage of oil seals
are due to careless fitting, and resulting damage to
both seals and sealing surfaces. Care in fitting is
essential if good results are to be obtained.
JOINTS AND JOINT FACES

1. Always use correct gaskets where they are
spccificd.
2. Use jointing compound only when recommended.
Otherwise fit joints dry.
3. When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4. Remove all traces of old jointing materials prior to
reassembly. Do not use a tool which could damage
joint faces.
5 . Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
swarf or dirt to enter tapped holes or enclosed
parts.
6 . Blow out any pipes, channels or crevices with
compressed air, renewing any 0-rings or seals
displaced by air blast.
10711
FLEXIBLE HYDRAULIC PIPES, HOSES
1. Before removing any brake or power steering hose,

clean end fittings and area surrounding them as
thoroughly as possible.
2. Obtain appropriate blanking caps before detaching
hose end fittings, so that ports can be immediately
covered to exclude dirt.
3. Clean hose externally and blow through with
airline. Examine carefully for cracks, separation of
plies, security of end fittings and external damage.
Reject any hose found faulty.
4. When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not twisted
before or during tightening of union nuts.
5. Containers for hydraulic fluid must be kept
absolutely clean.
6. Do not store hydraulic fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7. Do not allow hydraulic fluid to be contaminated
with mineral oil, or use a container which has
previously contained mineral oil.
8. Do not re-use fluid bled from system.
9. Always use clean brake fluid to clean hydraulic
components.
10. Fit a blanking cap to a hydraulic union and a plug
to its socket after removal to prevent ingress of
dirt.
11. Absolute cleanliness must be observed with
hydraulic components at all times.
12. After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to the
brakes (engine running) and operates the steering.
METRIC BOLT IDENTIFICATION
1. An I S 0 metric bolt or screw, made of steel and

larger than 6 mm in diameter can be identified by
either of the symbols I S 0 M or M embossed or
indented on top of the head.
2. In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade e.g. 8.8, 10.9, 12.9 or 14.9,
where the first figure gives the minimum tensile
strength of the bolt material in tens of kg/sq mm.
3. Zinc plated I S 0 metric bolts and nuts are chromate
passivated, a greenish-khaki to gold-bronze colour.
ST1035M
1071
GENERAL FIITING INSTRUCTIONS

~
~~
METRIC NUT IDENTIFICATION
1. A nut with an I S 0 metric thread is marked on one

face or on one of the flats of the hexagon with the
strength grade symbol 8 , 1 2 or 14. Some nuts with a
strength 4, 5 or 6 are also marked and some have
the metric symbol M on the flat opposite the
strength grade marking.
2 A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers o r a face of the nut is marked in
a position relative to the appropriate hour mark on
a clock face to indicate the strength grade.
3. A dot is used to locate the 12 o'clock position and a
dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o'clock position.
STl036M
HYDRAULIC FITTINGS -Metrication

WARNING: Metric and Unified threaded hydraulic
parts. Although pipe connections to brake system units
incorporate threads of metric form, those for power
assisted steering are of UNF type. It is vitally important
that these two thread forms are not confused, and
careful study should be made of the following notes.
Metric threads and metric sizes are being introduced

into motor vehicle manufacture and some duplication
of parts must be expected. Although standardisation
must in the long run be good, it would be wrong not to
give warning of the dangers that exist while UNF and
metric threaded hydraulic parts continue together in
service. Fitting UNF pipe nuts into metric ports and
vice-versa should not happen, but experience of the
change from BSF to UNF indicated that there is no
certainty in relying upon the difference in thread size
when safety is involved.
To provide permanent identification of metric parts is
easy hut recognitinn has been assistpd h\r
" J the
following means. (Illustration A Metric, B Unified.)
1. All metric pipe nuts, hose ends, unions and bleed
screws are coloured black.
2. The hexagon area of pipe nuts is indented with the
letter 'M'.
3. Metric and UNF pipe nuts are slightly different in
shape.
4
ST1033M
ST1034M
The metric female nut is always used with a trumpet

flared pipe and the metric male nut is always used with
a convex flared pipe.
4. AI1 metric ports in cylinders and calipers have no
counterbores, but unfortunately a few cylinders
with UNF threads also have no counterbore. The
situation is, all ports with counterbores are UNF,
but ports not counterbored are most likely to be
metric.
5. The colour of the protective plugs in hydraulic
ports indicates the size and the type of the threads,
but the function of the plugs is protcctive and not
designed as positive identification. In production it
is difficult to use the wrong plug but human error
must be taken into account.
The Plug colours and thread sizes are:
UNF
iinx24UNF
RED
GREEN 6 in x 20 UNF
YELLOW 4 in x 20 UNF
PINK
B in x 18 U N F
METRIC
BLACK 1Ox 1 mm
GREY
1 2 x 1 mm
BROWN 14 x 1,5 mm
6. Hose ends differ slightly between metric and UNF.
Gaskets are not used with metric hoses. The UNF
hose is sealed on the cylinder or caliper face by a
copper gasket by the metric hose seals against the
bottom of the port and there is a gap between faces
of the hose and cylinder.
Pipe sizes for UNF are & in, in and & in outside
diameter.
Metric pipe
. . sizes are 4,75 mm, 6 mm and 8 mm.
4,75 mm pipe is exactly the same as
in pipe.
6 mm pipe is 0.014 in smaller than i in pipe. 8 mm
-.
pipe is 0.002 in larger than & in pipe.
Convex pipe flares are shaped differently for
metric sizes and when making pipes for metric
equipment, metric pipe flaring tools must be used.
c-
f J'
ST1031 M
Ei
ST1030M
NUTS
ST1032M
The greatest danger lies with the confusion of

10 mm and 2 in UNF pipe nuts used for
in (or
4,75 mm) pipe. The 3 in UNF pipe nut or hose can
be screwed into a 10 mm port but is very slack and
easily stripped. The thread engagement is very
weak and cannot provide an adequate seal.
The opposite condition, a 10 mm nut in a in port,
is difficult and unlikely to cause trouble. The 10 mm
nut will screw in 1; or 2 turns and seize. It has a
crossed thread feel and it is impossible to force the
nut far enough to seal the pipe. With female pipe
nuts the position is of course reversed.
The other combinations are so different that there is
no danger of confusion.
-,
KEYS AND KEYWAYS

1. Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to refit
key.
2. Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.
TAB WASHERS
1. Fit new washers in all places where they are used.
Always renew a used tab washer.
2. Ensure that the new tab washer is of the same
design as that replaced.
SPLIT PINS
. .....::.
.;a .... ., .
7:
1. Fit new split pins throughout when replacing any

unit.
2. Always fit split pins where split pins were originally
used. Do not substitute spring washers: there is
always a good reason for the use of a split pin.
3. All split pins should be fitted as shown unless
otherwise stated.
1. When tightening a slotted or castellated nut never

slacken it back to insert split pin or locking wire
except in those recommended cases where this
forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should be
selected, or washer thickness reduced.
2. Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved nuts

should be tightened in accordance with special
instructions.
LOCKING WIRE
1. Fit new locking wire of the correct type for all
assemblies incorporating it.
2. Arrange wire so that its tension tends to tighten the
bolt heads, or nuts, to which it is fitted.
SCREW THREADS
1. Both UNF and Metric threads to I S 0 standards are
used. See below for thread identification.
2. Damaged thrcads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and is
not recommcndcd.
3. Always ensure that replacement bolts are at least
equal in strength to those rcplaced.
4. Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action on
screwing in the bolt or stud could split the housing.
5 . Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
6 . To check or re-tighten a bolt or screw to a specified
torque figure, first slacken a quarter of a turn, then
re-tighten to the correct figure.
7. Always oil thread lightly before tightening to
ensure a free running thread, except in the case of
self-locking nuts.
1071
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface of
the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of the
nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter for
a short length at its extremity.
.
.
ST1039M
RECOMMENDED LUBRICANTS AND FLUIDS
Service instructions for temperate climates -ambient temperature range -10C to 35C
COMPONENTS
I CASTROL
BP
Engine V8
Carburetter
Dashpots
(15W/50) or
Nova
llOW/40\
Engine
4-cyl. pctrol
Engine
4-cyl. diesel
DUCKHAiMS
Superlube
(15W/40)
Duckhams
15W/SO
Hypergrade
Motor Oil
Esso
Superlube
(15W/40)
'LT77-fivespeed gearbox
Duckhams
15w/50
Hypergrade
Motor Oil or
Duckhams
Fleetol Multi-V
20Wi50 or
Duckhams
Fleet Master
15w/40
Duckhams
Q-Matic
'LT95 - fourspeedgearbox
including transfer
box
Duckhams
15W/50
Hypergrade
Motor Oil
Front differential
Rear differential
jwivel pin
iousings and
-R30R & LT23OT
rransfer box
2T85 -five,peed gearbox /8 cylinder
3ils lisled on lines marked (*) may
:rant and rear
!P
mergrease
-2
Castrol
LM Grease
Duckhams
LB 10
lteering box
Manual)
% PGear Oil
#AB90EP
Castrol
HYPOY
SAE 90EP
Duckhams
Hypoid 90
Castrol
T O Dexron IID
Duckhams
Fleetmatic C D
or
Duckhams
D-Matic
Duckhams
I5W/50
Hypergrade
Motor Oil
iir cleaner
-cyl. petrol
DX 2D
UP Visco
Castrol GTX
(15W/5!)or
Castrolite
( 10W/40)
(15W/40)or
P Visco
i r cleaner
-cyl. diesel
(IOW130)
BP Visco
Castrol GTX
(15W150) or
Castrolitc
( I Uw140)
(15W/40) or
I BP Visco
rake and clutch
reservoirs
Lubrication nipples
(hubs, ball joints,
etc.)
.,
Fina
Supergradc
Motor Oil
10W/40 or
15W/40
Fina
Supergrade
MotorOil
1OW/40 or
15W140
Shell Super
Motor Oil
15W/40 or
IOW140
Shell Super
Motor Oil
15W/40 or
low140
Supergrade
Shell Super
Motor Oil
1OW/40 or
15W/40
RimulaX
Havoline
Motor Oil
15W/40 or
Eurotex HD
10WBO
Tvoe G
Esso
Superlube
(15W140)
Duckhams
Hypergrade
15W/50
Mobil
Super
IOW140
Mobil
Mobilube
HDW
Esso
Superlube
15W/40
II
Esso
Multipurposc
I Grease
Esso
Gear Oil
s5w/90
GX
Fina
Supergrade
Motor Oil
10W/40 or
15w/40
Fina
Pontonic MP
ISAEXOW/90
Shell Super
Motor Oil
15W/40 or
1OW/40
Shell
Fina
Supergrade
Motor Oil
10W/40 or
15W/40
Shell
Super
Multigrade
15w/40
or
10W/40
Mobil-
11 Y;; 11
Mobil
Mobilube
HD9U
plus
15Wi40 o r
Eurotex
Motor Oil
town0
Mobil
Super
10w/40
I-
Havoline
Motor Oil
i15W/40
or Mobil 1
Rally
Formula
Esso
Gear Oil
GX
35w/90
so be used in LTZ! transfer box.
Castrol
GTX
(15W/50)
1 1
Super
10W/40 or
Kally
Formula
15W/50
Mobil
Super
10W/40or
Mobil 1 Rally
Formula
15W/40
IT E X A C ~
I SHELL
PETROFINA
MOBIL
Super
Duckhams
Hypoid 90
3P Visco
!Ooo
15W/40) or
3P Visco
(ova
10W/40)
'ower steering
uid reservoir
s applicable
ESSO
Duckhams
15W/S0
Hypergrade
Motor Oil
; %1
I
Fina
Pontonic MP
/SAESOW/9O
Shell
Havoline
Motor Oil
1SW140 or
Eurotex HD
IOW/30
Texaco
Multigear
Lubricant
E P 85W190
Havoline
Motor Oil
15W/40
or
Eurotex HD
10W/30
Marfak
All purposc
Grease
Texaco
Multigear
Lubricant
EP 85W/90
Texamatic
Fluid 9226
i
Mobil
ATF 220 D
Dexron IID
Esso
Superlube
(15W/40)
Mobil
Super
15W/40
or 1OW/40
Fina
Dexron IID
Fina
Supergrade
Motor Oil
15W/40or
10W/40
Shell
ATF
Dexron IID
Shell Super
Motor Oil
15W/40or
1OW/40
Havoline
Motor Oil
low130 or
Eurotex HD
lowno
15W/40 or
Havoline
Motor Oil
15W/40 or
10W/30 or
Eurotex HD
1OW/30
Shell
Ketinax A
Marfak
All purpose
Grease
Owl40
Universal Bra ! I h i d or other brake fluids having a minimum boiling point of 260C (500F)
3
and comnlvine with FMVSS 116 DOT
~~.
P
Castrol
Duckhams
Esso
MobilFina
Energrease
LM Grease
LU 10
Multigrease MP
Marson
L2
pumosc
HTL 2
I Top link
Cooling system
Anti-freeze
Universal Anti-freeze
See under Anti-freeze section 09.
09 I
RECOMMENDED LUBRICANTS, FLUIDSAND CAPACITIES
1l 1l
1I
SPEC. REF.
COMPONENTS I BP
CASTROL DUCKHAMS ESSO
MOBIL
Castrol
Duckhams
Esso
Mobil
Windscreen hinges BP
Shell
MultiMobilVentilator hinges Energrcase LM Grease LB 10
Marson
Retinax
purpose grease
Ventilator control L2
HTL2
Grease MP
Seat slides. Hood
H
retention clips
Door lock striker
All Seasons Screen Washer Fluid
Windscreen
washers
I Graohite Lock Grease Tvoe 'B'
Bonnet ointle
Door locks
DO NOT LUBRICATE. These components are 'life' lubricated at the manufacturing stage
(anti-burst)
Inertia reels
~~
Battery lugs
Earthing surfaces
Where paint has
been removed
Air Conditioning
System
Refrigerant
Compressor Oil
;
;
SERVICE INSTRUCTIONS ALL MARKETS
TEXACO
BRANDS
Marfak
NGLI-2
Multi-
based
~~~~
~~
Petroleum jelly.
NOTE: Do not use Silicone Grease
~-
METHYLCHLORIDE REFRIGERANTS MUST NOT BE USED

Use only refrigerant 12. This includes 'Freon 12' and Arcton 12'
Shell Clavus 68 BP Energol LPT 68 Sunisco 4GS Texaco Capella E Wax Free 68
C --" .
~

SERVICE INSTRUCTIONS FOR AMBIENT CONDITIONS OUTSIDE TEMPERATE CLIMATE LIMITS
OR FOR MARKETS WHERE THE PRODUCTS LISTED ARE NOT AVAILABLE
COMPONENTS
Engine
SERVICE CLASSIFICATION WORLDWIDE
PERFORMANCE LEVEL
Petrol
Diesel
SAE VISCOSITY
sw120 swi30
Carburetterdashpotr oils must meet L I Oils must meet BI . 5Wl40
Cars spec.
Cars spec.
Oil can
BLS.22.OL.02
BLS.22.OL.02 an( 10w130
Oils
or
MIL-L-461S2A or
Oil bath air cleaners API service levcls API service levels 10w140 low150
SE or SF or SEICC CC or CD or
or SFICC or SEICD SEICC or SE/CD 15w140 1sw150
or SFICC or SFICC
or S F K D
or the CCMC
or the CCMC
20W/40 20Wi50
requirements
requirements
Power steering
ATF M2C 33 F o r G
reservoir
90 EI'
API GL4
Front and rear
Axle differential
or
Swivel pin housing MIL-Ir2105
80W EP
LT230 transfer bo,
Steering box
LI77 eearbox
ATF M2C 33 F or G
Oils must mcet BL
L'l%iearbox
10W130 IOW140
IOWlS0
Cars spec.
including
BLS.22.OL.02 or
:ransfer box
API service levels
IOW140 IOW150
SE or SF or SE/CC
1sw140 15w150
or SEICD or SF/CC
2ow140 20w150
or SFICD
or the CCMC
requirements
1ow130 10w140
LT85 gearbox Oils must meet L
Cars spec.
1ow15o
V8 cylinder
BLS.22.OL.02 or
API servicc levels
SE or SF or SEICC
?r SE!C_n or SE!CC
3r SWCD or thc
X M C requirements
Brake fluid must have a minimum boiling point of
3rake and clutch
260C (500F)and comply with FMVSS 116 DOT 3
eservoirs
xbrication nipples VLGI-2 multipurpose lithium based grease
hubs, ball joints, etc)
~~~
AiMIENT TEMPERATURE "C

-30" -20"
-10"
0"
10"
20"
30"
40"
50"
RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES
109I
ANTI-FREEZE
Use only UNIVERSAL Anti-freeze or an Ethylene Glycol based anti-freeze, containing no methanol, with
non-Phosphate corrosion inhibitors suitable for use in cast iron and aluminium alloy engines to ensure protection of
the cooling system against frost and corrosion.
Engine
4-cyl. Engines (cast iron)
V8 Engine (aluminium)
Mixture
One part anti-freeze two parts water
Percentage
Concentration
33%
One part anti-freeze one part water
50%"
One part anti-freeze one part water
50% "
Protection
Down to -20C
Below -20C to
-36C
Down to -36C
IMPORTANT: Coolant solution must not fall below proportions of one part anti-freeze to three parts water, i.e. min.
25" anti-freeze in coolant, otherwise damage to engine is liable to occur.
!..
CORROSION INHIBITOR
.......
... . ".
.I
I,
.I
:.. .!,'
I.
When anti-freeze is not required the cooling system must be flushed out with clean water and filled with a solution of
ONE PART MARSTONS SQ 36 inhibitor to NINE parts water to provide a 10" mixture concentration.
CAPACITIES
The following capacity figures are approximate and are provided as a guide only. All oil levels must be set using the
dipstick o r level plugs as applicable.
Component
Engine sump oil, 4-cylinder.. .............................................
Extra when refilling after fitting new filter, 4-cylinder.. ............
Air cleaner oil, 4-cylinder .................................................
Engine sump oil, V8 cylinder .............................................
Extra when refilling after fitting new filter, V8 cylinder.. ..........
Main gearbox oil, five-speed .............................................
.._.
...
Transfer box oil, LT230R five-speed main gearbox.. ...............
..
... . .. .....,
....
:. :
.......
LT85 five-speed gearbox ..................................................
LT230T transfer gearbox ..................................................
Main gearbox oil, four-speed .............................................
Transfer gearbox oil, four-speed main gearbox ......................
Front differential ............................................................
Rear differential: Salisbury 8HA ........................................
Swivel pin housing oil (each) .............................................
Fuel tank, rear ...............................................................
Fuel tank, side (except Station wagon) .................................
Fuel tank, side (Station wagon only) ..................................
Cooling system, 4-cylinder petrol models (standard) ...............
Cooling system, 4-cylinder diesel models and heavy duty
petrol models ..............................................................
Cooling system, V8 cylinder modcls.. ..................................
Steering box manual.. ......................................................
Power steering box and reservoir fluid .................................
Litres
Imperial unit
6,OO
0,85
0,85
5,lO
0,56
2,20
2,80
3,OO
2,80
2,60
3,16
1,70
2,30
0,35
79,50
68,20
45,50
10,30
11 .OO pints
1.50 pints
1.50 pints
9.00 pints
1.00 pint
3.90 pints
4.90 pints
5.25 pints
4.9 pints
4.70 pints
5.50 pints
3.00 pints
4.00 pints
0.60 pint
17.50 gallons
15.00 gallons
10.00 gallons
18.00 pints
11,oo
12,80
O,43
2,90
19.00 pints
22.50 pints
0.75 pints
5.0 pints
(.
.......
.,. .....
..,?
. . .. '.
MAINTENANCE
I10I
MAINTENANCE SCHEDULES
Revised Maintenance Schedules are introduced with the commencement of the Land Rover Ninety V8 model range.
The new schedules also apply to four-cylinder, petrol and diesel models, and feature a reduced 10.000 km
(6,000 miles) service. The new schedules supersede previous issues.
Efficient maintenance is one of the biggest factors in ensuring continuing reliability and efficiency. For this reason
the following detailed schedules are included so that at the appropriate intervals owners and operators may know
what is required. The Maintenance Schedules are based upon intervals of 10.000 km (6,000 miles) or 6 months
unless otherwise stated.
Note: The 10.000 km service must be repeated every 10.000 km (6,000 miles) or six months, whichever is first.
The 20.000 km service must be repeated every 20.000 km (12.000 miles) or 12 months, whichever is first, with
additional maintenance at the intervals specified in the schedule.
Every
1O.OOo km
(6.0" miles)
or6months
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Every
20.000 km
(12.000 miles)
or 12months
0Check condition and security of seats, seat

belt mountings, seat belts and buckles
0Check operation of all lamps
Check operation of horns

Check operation of warning indicators
Check operation of windscreen and rear
wipers and washers
Check condition of wiper blades
Check security and operation of handbrake
Check rear view mirror(s) for security,
cracks and crazing
Check operation of all doors, bonnet and
tailgate locks
Check operation of window controls
Lubricate all locks (not steering lock)
hinges and door -check mechanisms
Lubricate accelerator control linkage and
pedal pivot
ChecWadjust tyre pressures including spare
ChecWadjust headlamp alignment
Check front wheel alignment
ChecWtop-up battery electrolyte
Remove battery connections, clean and
grease (refit)
Removeroadwheels
U Check tyres comply with Manufacturer's
specification
Check tyres visually for cuts, lumps, bulges,
uneven wear and tread depth
Remove road wheel brake drums, wash out
dust, inspect shoes for wear and drums for
condition
Inspect wheel cylinders for fluid leaks
Inspect brake pads for wear, calipers for
leaks, and discs for condition
Refit road wheel brake drums
Adjust road wheel brakes
Adjust handbrake if required
Refit road wheels to original position
Renew engine oil
Renew engine oil filter
0
0
0
0
0
0
0n
0
0
0
0
a0
0
0.
0
U0
0
0
0
0
n
n
0
0
Every 4O.wO km
24.000ml
Every
1O.ooO km
(6.000 miles)
--
or6months
31
32
33
34
35
36
37
Every
20.000 km
(12,000 miles)
or 12month;
U U ChecWtop-up gearbox oil

Every 40.000 km
24.000 ml
a0
Renew transfer box oil

CheeWtop-up transfer box oil
Every 40.003 km
Renew front axle oil
24.lXXl ml
ChecWtop-up front axlc oil
Every 4O.lXK) km
Renew swivel pin housing oil
24.WOml
ChecWtop-up swivel pin housing oil
Every 40.000 km
Renew rear axle oil
38
2 4 , ~ m l
ChecWtop-up rear axle oil
39
40
Lubricate rear suspension upper link ball joint
Every 4O.OlKl km
Lubricate propeller shaft sealed sliding joints
41
24.000 ml
Lubricate propeller shaft universal joints
42
Lubricate handbrake mechanical linkage
43
Check visually brakc, fuel, clutch
44
pipeshnions for chafing, leaks and corrosion
45
U Check exhaust system for leakage and
security
46
U Check for oil leaks from engine and
transmission
47
Check for oil/fluid leaks from stcering and
suspension systems
48
U Check axlc breather pipes, ensure they arc
not blocked, pinched or split
Check security and condition of suspension
49
fixings
50
U Check condition and security of steering unit,
joints and gaiters
51
U Check tightness of propeller shaft coupling
bolts
U Clean fuel sedimenter (Diesel only)
52
Every 80.0Wkm
53
48,000 m
l
Clean electric fuel pump filter
54
U Renew fuel filter element (Petrol)
Drain flywheel housing if drain plug is fitted
55
for wading (refit)
Clean camshaft drive belt housing filter
56
(Diesel)
Check c~ndltienef heater p ! ~ gwiring fs:
fraying, chafing and deterioration
(diesel only)
58
U Remove heater plugs, clean, test and refit
(diesel only)
Every40.000 km
Remove diesel injectors, clean, test and refit
59
24.000ml
00
00
00
a0
0
00
D
00
0
Renew gearbox oil
El MAINTENANCE
Every
1O.ooO km
(6.000 miles)
or 6 months
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
Every
20.000 km
(12.000 miles)
or I2 months
0
- Renew fuel filter element (Diesel)
Checkladjust valve clearance (all models

except V8)
Cleardadjust spark plugs
Renew spark plugs
Renew air cleaner elements
Check air cleaner dump valve, clean or renew
Renew engine breather filter (V8)
Clean engine breather filter (all models
except V8)
Renew engine flame trap(s) (V8)
Renew brake Servo filter
Check brake Servo hose for security and
condition
Check air injection/pulsair system
hoses/pipes for security and condition
Check operation of pulsair check valves
Check crankcase breathing system for leaks,
hoses for security and condition
Top-up carburetter piston dampers
ChecWtop-up cooling system
Checktop-up fluid in power steering reservoir
Checktop-up steering box (manual steering)
ChecWadjust steering box
Check/top-up clutch fluid reservoir
Checktop-up brake fluid reservoir
Check/top-up windscreen and rear washer
reservoir
Check cooling and heater system for leaks,
hoscs for security and condition
Check power steering system for leaks,
hydraulic pipes and unions for chafing and
corrosion
Check condition of driving belts - adjust if
required (not camshaft drive belt - diesel)
Check ignition wiring and HT leads for
fraying, chafing and deterioration
Clean distributor cap, check for cracks and
tracking
0
0
0
0
EveryJ0.000
0
0
Every60.000
24,001)ml
km
km
36.000ml
0
00
0
00
0
0
00
00
00
0
00
00
0
0
Every
IO.o(K) km
(6.000 miles)
or 6 months
87
88
89
90
91
Every
2O.ooO km
~12.ooOmiles)
b r 12 months
0Clean/adjust distributor points (not V8)
Every 41.000 km
24.lXM ml
Renew distributor points (not V8)

Lubricate distributor (not V8)
Check voltage drop between coil CB and earth
Check dwell angle - adjustas necessary
(not V8)
ChecWadjust ignition timing
Note: It is important that the ignition timing,
dwell angle and carburetter adjustments are set
in accordance with the vehicle engine spenfcation
and fuel Octane rating. Refer to the relevant repair
operation manual for details
Check throttle operation
ChecWadjust engine idle speed, and
carburetter mixture settings with engine at
normal running temperature
Check operation of air intake temperature
control system (V8)
Carry out road or roller test - Check:
For excessive engine noise
Clutch for slippindjudder/spinning
Gear selectiodnoise - high and low range
Steering for noise/abnormal effort required
All instruments, pressure, fuel and
temperature gauges, warning indicators
Heater and air conditioning systems
Heatedrearscreen
Shock absorbers (irregularities in ride)
Foot brake, on emergency stop, pulling to
one side, binding, pedal effort
Handbrakeefficiency
Operation of inertia seat belts
Roadwheel balance
Transmission for vibrations
For body noises (squeaks and rattles)
Fuel governor cut-off point
For excessive exhaust smoke
Engineidlespecd
Endorse service rccord
a .
-.:/
Report any additional work required
92
0
00
93
94
00
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
00
00
00
00
00
00
00
00
00
00
00
a
00
00
00
00
00
0
0a
c3
:
WARNING: Two-wheel roller tests must be restricted to 5 k d h (3 m.p.h.) because the Land Rover One Ten and
Ninety is is constant four-wheel drive.
At 100.000 km (60?000 mile) intervals it is imperative that the camshaft drive belt be renewed, failure to do so
could result in serious engine damage.
RECOMMENDATIONS
At 30.000 km (18,000 mile) intervals or every 18 months, whichevcr is the sooner, the hydraulic brake fluid should
be completely renewed.
At 40.000 km (24,000 mile) intervals remove the Pulsair injection manifold and connecting pipes, ensure that the
internal bores and the cylinder head drillings are clean and free from obstructions, clean as necessary and refit.
(Emission control V8 petrol engines)
At 60.000 km (36,000 mile) intervals or every 3 years, whichever is the sooncr, all hydraulic brake fluid, seals and
flexible hoses should be renewed. all working surfaces of the master cylinder, wheel cylinders and caliper cy!inders
should be examined and renewed where necessary.
At 60.000 km (36,000 mile) intervals remove all suspension dampers, test for correct operation, refit or renew as
necessary.
Vehicles fitted with free wheeling front hubs
The hubs require no routine maintenance. When the hub bearings are adjusted, or any time the vehicle has been
used for wading, the moving parts of the free wheel hubs should be lightly smeared with Rocol 1000 grease or a
similar molybdenum disulphide bearing grease.
2
&"-?
E.
-..
''
MAINTENANCE
,;:,.:.>,
a;,-;. :?
LUBRICATION
. ..,......
<.
This first part of the maintenance section covers

renewal of lubricating oils for the major units of the
vehicle and other components that require lubrication,
as detailed in the Maintenance schedules. Refer to the
General specification data for capacities and
recommended lubricants.
Vehicles operating under severe conditions of dust,
sand, mud and water should have the oils changed and
lubrication carried out at more frequent intervals than
that recommended in the maintenance schedules.
Draining of used oil should take place after a run when
the oil is warm. Always clean the drain and filler-level
plugs before removing. In the interests of safety
disconnect the vehicle battery to prevent the engine
being started and the vehicle moved inadvertently,
while oil changing is taking place.
Allow as much time as possible for the oil to drain
completely except where blown sand or dirt can enter
the drain holes. In these conditions clean and refit the
drain plugs immediately the main bulk of oil has
drained.
Where possible, always refill with oil of the make and
specification recommended in the lubrication charts
and from sealed containers.
Renew oil filter -V8 and 2.5 Diesel engines
5. Place an oil tray under the engine.

6. Unscrew the filter anti-clockwise, using a strap
spanner as necessary.
7. Smear a little clean engine oil o n the rubber washer
of the new filter, then screw the filter on clockwise
until the rubber sealing ring touches the machined
face, then tighten a further half turn by hand only.
Do not overtighten.
Illustration A. V8 engine.
RENEW ENGINE OIL AND FILTER
DRAIN THE OIL -All engines

1. Drive vehicle to level ground.
2. Run the engine to warm the oil; switch off the
ignition and disconnect the battery for safety.
3. Place an oil tray under the drain plug.
4. Remove the drain plug in the bottom of the sump
at the left-hand side - V8 and right-hand side
4-cylinder engines. Allow oil to drain away
completely and replace the plug and tighten to the
correct torque.
Gi
ST1022M
Illustration B. 2.5 Diesel engine.
NOTE: The example shown below is a 4 cylinder engine

sump.
ST 918M
1x1
MAINTENANCE
Renew oil filter -2.25 petrol and diesel engine
8. Place oil tray under engine.

9.
10.
11.
12.
Unscrew filter retaining bolt.

Remove the container.
Remove the element.
Discard the used filter element and large rubber
washer.
13. Wash the container in kerosene.
14. Place the new filter element in the container and
reassemble the unit, using the new large rubber
washer supplied with the element.
15. Ensure that all the sealing washers are in position
and intact, and that the container is correctly
located in the adaptor.
16. Tighten the filter retaining bolt to the correct
torque. Do not overtighten.
models
17. Check that the drain plug is tight.

18. Clean the outside of the oil filler cap, remove it
from the rocker cover and clean the inside.
19. Pour in the correct quantity of new oil of the
correct grade from a sealed container to the high
mark on the dipstick and firmly replace the filler
cap.
20. Run the engine and check for leaks from the filter.
Stop the engine, allow the oil to run back into the
sump for a few minutes, then check the oil level
again and top up if necessary.
DRAIN AND REFILL LT77mm MAIN GEARBOX

4-cylinder engines
1. Drive the vehicle to level ground and place a

suitable container under the gearbox to catch the
old oil.
2. Remove the gearbox and extension case drain
plugs and allow the oil to drain completely. Wash
the extension case filter in kerosene and refit the
plugs using new washers, if necessary, and tighten
to the correct torque.
ST 919M
Sl
Refill sump with oil -all
RENEW MAIN AND TRANSFER GEARBOX OILS
3 . Remove the oil filler-level plug and inject the

approximate quantity of new oil of the correct
make and grade until it begins to run out of the
filler-level hole. Fit the plug and tighten to the
coirect torque. Since the plug has a tapered thread
it must not be overtightened. Wipe away any
surplus oil.
MAINTENANCE
110I
DRAIN AND RENEW 230R AND 230T TRANSFER

GEARBOX (4-cylinder engine)
DRAIN AND RENEW LT95 TRANSFER GEARBOX

OIL

container under the gearbox to catch the old oil.
2. Remove the drain plug and allow the oil to drain.
Fit the plug using a new washer, if necessary, and
tighten to the correct torque.
3. Remove the filler-level plug and inject the
approximate quantity of the recommended oil until
it begins to run from the plug hole. Fit the level
plug and tighten only to the correct torque, do not
overtighten, wipe away any surplus oil.
1. Drive vehicle to level ground and place a container

beneath the gearbox to catch the old oil.
2. Remove the drain plug and allow time for the oil to
drain completely.
3. Clean and refit the drain plug using a new washer,
if necessary and tighten to the correct torque.
4. Remove the oil filler-level plug and inject the
approximate quantity of a recommended oil until it
begins to run from the hole. Clean and fit the plug
and tighten to the correct torque. Do not
overtighten. Wipe away any surplus oil.
ST1070M
DRAIN AND RENEW LT95 MAIN GEARBOX (V8

engines)
container under the gearbox to catch the old oil.
2. Remove the drain plug, washer and filter from the
bottom of the gearbox casing and allow the oil to
drain completely.
3. Wash the filter in petrol, allow to dry and fit to the
casing. Using a new washer, if necessary, fit the
plug and tighten to the correct torque.
4. Remove the oil filler-level plug from the side of the
gearbox and inject the approximate quantity of the
correct oil until it begins to run from the filler-level
hole. Clean and refit the plug using a new washer
and tighten to the correct torque. Wipe away any
surplus oil.
RENEW FRONT AND REAR AXLE OIL

container under the axle to be drained.
2. Using a spanner with a 13 mm (0.5 in) square drive
remove the drain plug and allow the oil to drain
completely. Clean and refit the drain plug.
3 . Remove the oil filler-level plug and inject new oil
of a recommended make and grade until it begins
to run from the hole. Clean and fit the filler-level
plug and wipe away any surplus oil.
NOTE: Whilst the illustration shows a 90 model
front differential, the procedure is the same for all
axles.
El
MAINTENANCE
RENEW SWIVEL PIN HOUSING OIL

container under each swivel housing to catch the
used oil.
2. Remove the drain plug and allow the oil to drain
completely and clean and refit the plugs.
3. Remove the oil filler-level plug and inject the
recommended make and grade of oil until oil
begins to run from the level hole. Clean and fit the
level plugs and wipe away any surplus oil.
TOP-UP MANUAL STEERING BOX
1. Remove the oil filler plug and observe the oil level
which should be 25 mm (1.0 in) below the top of
the filler hole.
2. If necessary top-up to the correct level with a
recommended oil. Clean and refit the plug and
wipe away any surplus oil.
S T 925M
//
RENEW AIR CLEANER OIL - 2.25 litre engines

(early models)
LUBRICATE PROPELLER SHAFTS

1. Clean all the grease nipples on the front and rear
propshaft universal joints, and sliding portion of
the rear shaft.
2 . Charge a low pressure hand grease gun with grease
of a recommended make and grade and apply to
the grease nipples.
3. Remove the screwed plug from the front shaft and
fit a suitable grease nipple.
4. Disconnect one end of the front propeller shaft and
compress the sliding portion whilst applying
grease. It is necessary to compress the shaft to
prevent over filling with grease. It should be noted
that this sliding portion must only be lubricated at
40.000 km (24,000 mile) intervals.
5. Reconncct the propeller shaft, remove the grease
nipple and fit the screwed plug.
1. Slacken wing nut and release the clamping strap

securing the complete air cleaner.
2 . Disconnect the outlet elbow from the intake pipe
and remove the clcaner from thc vehicle.
3. Remove the oil bowl from the bottom of the
cleaner by releasing the three securing clips.
4. Clean all dirty oil and sludge from the bowl and
refill with fresh engine oil to the level indicated by
a ring formed in the pressing; the capacity is
approximately 0,85 litre (1.5 imperial pints).
5. Clean the spiral in the cleaner body by swilling the
complete body in paraffin and shake off the
surplus.
6. Remove and clean the air intake cap.
7. Clean the wire mesh filter.
8. Reassemble filter using a new scaling ring.
9. Refit the complete unit into the vehicle.
ct
-d
MAINTENANCE
:.
L
7
X
p
'.
.. .
..':?
..-I
1
.
1
,
TOP-UP BRAKE VACUUM PUMP OIL

Diesel engine
- 2.25 litre
1. Slacken the drive belt, and the pump pivot bolts

and nuts and slip the belt from the pulley.
2. Move the pump to an upright position and
temporarily tighten the nuts and bolts to maintain
this position.
3. Turn the pump pulley so that the indicating marks
on the pulley hub and pump body line up.
TOP-UP CARBURETTER PISTON DAMPER

only
I10I
- V8
1. Unscrew the cap on top of both suction chambers

and withdraw the damper.
2. Top-up the reservoir with engine oil to within
12 mm (0.5 in) from the top of the hollow piston
rod. Refit the damper and secure the cap.
-.
.
'...
. . ..
I,
:, :'
RENEW LT85 MAIN GEARBOX OIL

4. Remove the oil level plug at the rear of the pump
and if necessary inject a recommended SAE
15W-50 oil up to the level of the hole.
5 . Refit the level plug, and fit and tension the drive
belt.
Drain and refill monthly when operating under severe

wading conditions.
To change the gcarbox oil proceed as follows:
1. Immediately after a run when the oil is warm, drain
off the oil into a container by removing the drain
plug and washer from the bottom of the gearbox
casing.
2. Remove the oil filter.
/4 4
ST 1008M
REAR SUSPENSION BALL JOINT

1. Apply a grease gun to the nipple using a
recommended grease.
.. ....
.~
,'*
... .._
.... .
3. Wash the filter in clean fuel; allow to dry and

replace.
4. Clean and refit drain plug and washer and refill
gearbox through the oil level/filler plug, with the
correct grade of oil, to the bottom of the oil
1eveYfiller hole. For capacity see Data Section.
7
MAINTENANCE
GENERAL MAINTENANCE AND ADJUSTMENT
13. Fit the road wheels, lower the vehicle and finally
tighten the wheel retaining nuts.
This second part of the maintenance section covers

adjustments and items of general maintenance as
dictated by the Maintenance Schedules. However,
only maintenance operations that are not included in
the Overhaul Sections of the manual appear in this
section.
EXAMINE AND RENEW FRONT BRAKE FRICTION

PADS
Examine the friction pads for wear and if less than
3 mm (0.125 in) thick or oil contaminated, they must
be renewed on both wheels at the same time, as
follows:
NOTE: See Book 4 Section 70 for latest method of

friction pad retension.
l.+Slackcn both front wheel nuts and jack-up the
vehicle and lower onto axle stands, and remove
whecls.
2. Clean the exterior of the calipers.
3. Remove the split pins from the brake caliper.
4. Remove the retaining springs.
5 . Withdraw the friction pads.
6. Clean the exposed parts of the pistons, using only
new brake fluid.
CLEAN AND CHECK AXLE BREATHERS

valve type (where fitted)
- ball
1. Clcan the outside of the breather and unscrew from

the axle tube.
2. Wash the breather in petrol and shake to ensure
that the ball valve is free.
3. Lubricate the ball with engine oil and refit to axle
tube.
7. Using piston clamp 186672 press each piston back

into its bore, whilst ensuring that the displaced
brake fluid does not overflow from the reservoir.
8. Smear the faces of the pistons with Lockheed disc
brake lubricant taking care not to !et any reach the
lining material.
9. Insert the new friction pads.
10. Place the friction pad retaining springs in position
and fit new split pins and splay the ends.
11. Apply the footbrake several times to locate the
pads.
12. Check the fluid reservoir and top-up if necessary.
8
Remote axle breathers - wherefitted

Pipes attached to the breathers on the axles terminate
at p i f i t s iiiside the chassis members oil eariy muueis
and into the engine compartment on later vehicles. This
allows the axles to breath whilst the vehicle is traversing
mud and water. No maintenance is required except to
ensure that the pipe: do not become blocked, kinked,
or split, or damaged in any other way to prevent proper
breathing.
,
CHECK STEERING BALL JOINTS
ADJUST REAR BRAKES
Ball joints are lubricated for the normal life of ball

joints during manufacture and require no further
lubrication. This applies only if the rubber gaiter has
not become dislodged or damaged. The joints should
be checked at the specified mileage intervals but more
frequently if the vehicle is used under arduous
conditions.
1. Check for wear in the joints by moving the ball
joint up and down vigorously. If free movement is
apparent renew the complete joint assembly.
Land Rover One Ten Vehicles
1. Raise up vehicle and lower onto axle stands.

2. Each shoe is independently set by means of a
hexagon adjuster. Check that the wheel turns
freely and turn one adjuster until the shoe is locked
against the drum. Slacken off the adjuster
sufficiently for the wheel to turn freely approximately two serrations on the snail cam.
3. Repeat the above procedure for the second brake
shoe and the opposite wheel.
4. Remove the axle stands and road test the vehicle
brakes.
"";
ST 926M
CHECK FRONT WHEEL ALIGNMENT
.-
Use recognised wheel alignment equipment to perform

this check and adjustment. See 'General Specification
and Data' section for the correct alignment. Check and
adjust with the vehicle on level ground.
1. Set the road wheels to the straight ahead position
and push the vehicle forward a short distance.
2. Slacken the clamp bolts securing the ball joints at
both ends of the track rod.
3. Twist the track-rod to decrease or increase its
effective length as required to achieve the correct
alignment.
4. Push the vehicle rearwards whilst moving the
steering wheel from side to side to settle the ball
joints. Then with the wheels in the straight ahead
position push the vehicle forward a short distance
and recheck the alignmcnt. If necessary make
further adjustments. When the alignment is correct
tighten the ball joint clamp bolts.
The ball joint pins must be central in their housing
and not inclined to one side. See section 57.
s-r
Land Rover Ninety Vehicles

The shoes are set by a single hexagon adjustment bolt
operating through a serrated snail cam enabling both
shoes to be adjusted to obtain the best results.
1. Raise-up the vehicle on to axle stands.
2. Check that the wheel rotates freely then turn the
adjuster until the brake shoes are in firm contact
with the drum.
3 . Slacken o f f the adjuster just sufficiently for the
drum to rotate freely.
4. Repeat the procedure for the other wheel.
5. Remove the axle stands and road test the vehicle.
MAINTENANCE
ADJUST TRANSMISSION BRAKE (Handbrake)
1. Set the vehicle on level ground and chock the
wheels.
2. Release the handbrake fully.
3. Remove the clevis pin connecting the handbrake
lever to the relay at the gearbox end.
\\ \\ \M\
6. Fit the clevis pin, washer and a NEW split

pin.
.
.
7. Slacken the adjuster 1 o r 2 notches until handbrake
shoes just clear the drum.
8. Apply the handbrake gradually. The drum should
still rotate on the first ratchet and start to come on
at the second ratchet.
CAUTION: DO NOT over adjust the handbrake, the
drum must be free to rotate when the handbrake is
released, otherwise serious damage will result.
DRAIN FLYWHEEL HOUSING
1. The flywheel housing can be completely scaled to
exclude mud and water under severe wading
conditions, by means of a plug fitted in the bottom
of the housing.
2. The plug should only be fitted when the vehicle is
expected to do wading or very muddy work.
i
3. When the plug is in use it must be removed
periodically and all oil allowed to drain off before
the plug is replaccd
4. Turn the adjuster on the back plate clockwise until

the shoes are fully expanded against the drum,
L-
Illustration A . 4-cylinder vehicles.
ifF
5 . Adjust the outer sheath of the handbrake cable by

means of the two locknuts at the gearbox end until
the holes in the clevis on the inner cable line up
with the hole in the relay lever.
Illustration B. V8 vehicles.
ST1074M
ST 1012M
10
4. When plug is not in use it should be stowed as

follows:
4 cylinder models -in tool kit
V8 -screwed into housing near drain hole.
&/
MAINTENANCE
Le I
--h.
I '^'
*.:
DRAIN ENGINE TIMING COVER -2.5 Diesel only
1. The timing cover can be completely sealed to

exclude mud and water under severe wading
conditions, by fitting a plug in the drain hole at the
bottom of the cover.
2. The plug should only be fitted when the vehicle is
expected to do wading or very muddy work.
3. When the plug is in use it must be removed
periodically and any oil present allowed to drain off
before the plug is replaced.
NOTE: There should not be any oil in the timing
cover, but if there is, the cause should be
investigated as soon as possible, as the timing belt
will deteriorate if it becomes contaminated with oil.
4. When the plug is not in use it should be stowed in
the tapped hole adjacent to the drain hole.
CLEAN ENGINE TIMING COVER FILTER

Diesel only
,
,
,:.
.I.
1101
1
ST209
RENEW AIR CLEANER ELEMENT - 2.5 Diesel and

2.25 Petrol engines
1. Disconnect the air cleaner hose.

2. Pull up the three clips and lift out the air cleaner
canister.
3 . Unscrew element wing nut and sealing washer.
4. Remove and discard the element. DO NOT
attempt to clean the element, fit a new one during
reassembly.
5 . Clean interior of canister.
6. Fit a new element and sealing washer.
- 2.5
I.:.
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A gauze filter is fitted at the bottom of the engine
timing cover to help prevent mud and other debris

entering the drain hole, when the wading plug is not in
use. The filter must be removed and cleaned
periodically, to ensure that it does not become blocked
and prevent the timing cover draining properly. Under
normal circumstances, the filter should be cleaned at
the intervals specified in the Maintenance Schedule or,
more frequently if the vehicle operates regularly in wet
or dusty conditions.
1. From underneath the vehicle, remove the four
bolts and plain washers and, withdraw the wading
plug plate from the bottom of the timing cover.
2. Wash the filter in kerosene or clean fuel. Brush off
any mud or other debris aiid ensure that the whole
filter is quite clean.
3. Check the condition of the gasket for the wading
plug plate. If necessary, fit a new gasket.
4. Refit the wading plug plate. Tighten the securing
bolts.
ST206
continued
11
MAINTENANCE
Check air cleaner dump valve
The dump valve provides an automatic drain for the air
cleaner and is fitted in the base of the air cleaner
support bracket.
7. Squeeze open the dump valve and check that the
interior is clean. Also check that the rubber is
flexible and in a good condition.
8. If necessary, remove the dump valve to clean the
interior. Fit a new valve if the original is in a poor
condition.
Check air cleaner dump valve
7. Squeeze open the dump valve and check that the

interior is clean. Also check that the rubber is
flexible and in a good condition.
8. If necessary, remove the dump valve to clean the
interior. Fit a new valve if the original is in a poor
condition.
t . ;,
Fit air cleaner
Fit air cleaner
9. Fir air cleaner canister and secure with the clips.

10. Connect the air cleaner hose.
RENEW AIR CLEANER ELEMENT -VS engine
1. Unscrew the two air cleaner strap retaining nuts.

2. Disconnect the air cleaner hose.
3. Remove the engine breather hose.
4. Withdraw air cleaner canister.
5. Unscrew element wing nut and washer and remove
filter seal.
6. Remove and discard the element. DO NOT
attempt to clean the element, fit a new one during
reassembly and secure with the wing nut.
9. Fit a new element and reassemble the air cleaner.

10. Fit the air cleaner canister.
11. Fit the breather hose.
12. Fit the air cleaner hose.
13. Secure with the retaining straps and nuts.
CLEAN FUEL LIFT PUMP SEDIMENT BOWL

Petrol engine -early vehicles
1. Remove the bowl by slackening the thumb screw

and swinging the retainer to one side.
2. Remove and clean the filter gauze in clean petrol.
3 . Ensure that the sealing washer is in good condition.
4. Replace gauze and refit the bowl.
5. Prime the pump by operating the hand lever.
ST1068M
12
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:?: 3
CLEAN ELECTRIC FUEL PUMP FILTER - V8 and

later 2.25 Petrol engine vehicles
The pump is located mid-way along the right hand side
of the chassis.
1. Release the three bolts and remove the protective
cover -except 90 models.
ST 1014M
RENEW FUEL FILTER ELEMENT

4-cylinder and V8
- Petrol engines
The element provides a filter between the pump and

carburetter and is located adjacent to fuel pump on the
right hand side of the chassis.
1. Release the three bolts and remove the protective
cover. See Clean electric fuel pump filter.
2. Unscrew the centre bolt.
3 . Withdraw the filter bowl.
4. Remove the small sealing ring and remove the
element.
5. Withdraw the large sealing ring from the underside
of the filter body.
6. Discard the old element and replace with a new
unit.
7. Ensure that the centre and top sealing rings are in
good condition and replace as necessary.
8. Fit new element, small hole downwards.
9. Refit sealing rings (small and large).
10. Replace filter bowl and tighten the centre bolt.
2. From beneath the vehicle disconnect the fuel inlet

pipe from the pump and blank the end of the pipe
by suitable means t o prevent fuel draining from the
tank.
3. Release the end cover from the bayonet fixing.
4. Withdraw the filter and clean by using a
compressed air jet from the inside of the filter.
5 . Remove the magnet (where fitted) from the end
cover and clean. Replace the magnet in the centre
of the end cover.
6 . Reassemble the fuel pump and refit the fuel inlet
pipe.
7. Use a new gasket for the end cover if necessary.
8. Fit the protective cover.
ST1075M
k G 2
13
10
MAINTENANCE
RENEW FUEL FILTER ELEMENT
-Diesel engines
Drain off Water
1. Slacken off drain plug to allow water to run out.

2. When pure diesel fuel is emitted, tighten drain
Plug-
FUEL SEDIMENTER
-Diesel engines (where fitted)
The sedimenter increases the working life of the fuel

filter by removing the larger droplets of water and
larger particles of foreign matter from the fuel.
Drain off water as follows:
Drain off Water
1. Slacken off drain plug to allow water to run out.

2. When pure diesel fuel is emitted, tighten drain
plug. Dismantle and clean as detailed below.
1
ST062
Renew filter
3. Support element holder.

4. Unscrew thc special bolt on top of the filter, the
element holder can now be removed.
5. Remove and discard the used element.
6 . Wash the element holder in petrol or fuel oil.
7. If necessary renew both the large rubber washer
and the small rubber washer in the filter top, also
renew the large rubber washer in the element
holder.
8. Push the new elcment onto the filter top spigot
with the holes in the element to the top.
9. Fit the element holder to the bottom of the
element, and secure with the special bolt.
10. Prime the system and check for fuel leaks.
ST 101 7M
-/
Clean element
3. Disconnect fuel inlet pipe at sedimenter and raise
pipe above level of fuel tank to prevent draining
from tank. Support in this positon.
4. Support sedimenter bowl and unscrew bolt on top
of unit and remove bowl.
5. Remove the sedimenter element.
6. Clean all parts in kerosene.
7. Fit new seals and reverse removal procedure.
8. Slacken off the drain plug, when pure diesel fuel
runs out tighten plug.
9. If necessary, prime the system.
10. Start engine and chcck for leaks from sedimenter.
w
4
14
ST 1018M
C u
MAINTENANCE
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RENEW DUCELLIER DISTRIBUTOR POINTS

4-cylinder engines
Renew Points
1. Release the spring clips and remove the distributor

cap.
2. Pull off the rotor arm.
3. Remove the dust shield.
4. Remove the retaining screw and remove the fixed
contact point.
5 . Slide the spring clip rearwards.
6. Disconnect the suppressor lead from the connector
block.
7. Disconnect the lead from ignition coil.
8. Remove insulation washer from the moving
contact point.
9. Lift off the moving contact point complete with
leads and connector block from the distributor
body.
10: Fit the new moving point over post.
11. Locate the leaf spring in the plastic guide.
12. Fit the insulation washer.
13. Secure the assembly with the spring clip.
14. Fit the connector block to the distributor body.
15. Connect ignition coil lead.
16. Fit suppressor lead to connector block.
17. Fit the fixed contact point and loosely retain with
the screw.
Adjust points
NOTE: The following two instructions describe the

adjustment of the contact points. The accompanying
illustration shows it being done with the aid of special
tool 18G1308. Whilst the points can be adjusted to the
datum setting only (see data) without the tool full
distributor adjustment, i.e. dwell angle, dwell variation
and vacuum advance can only be achieved by using this
tool in conjunction with engine diagnostic equipment. It
is essential that the above adjustments are carried out in
order to maintain correct emission levels and maximum
engine efficiency.
18. Rotate the engine until a cam of the rotor fully

opens the points.
19. Using a feeler, adjust the position of the fixed
contact point to the datum setting and tighten the
retaining screw.
20. Check and adjust the dwell angle, dwell variation
and vacuum advance.
15
El
MAINTENANCE
ADJUST DUCELLIER DISTRIBUTOR

Petrol engine
- 4-cylinder
Service tool:
1861308
Check and Adjust Dwell Angle
NOTE: The following six instructions can only be

carried out using engine diagnostic equipment and
special tool 18G1308.
1. Start the engine, disconnect the vacuum pipe from
the vacuum unit and with the engine idling check
the dwell angle - see data. If adjustment is
required stop the engine, remove the distributor
cap, rotor arm and dust cover, slacken the fixed
contact retaining screw and using the eccentric-post
end of the special tool, as illustrated, make an
appropriate adjustment. Tighten the retaining
screw, reassemble the distributor and recheck the
dwell angle.
Check vacuum advance
NOTE: If the vacuum unit has been removed or the

distributor dismantled, the vacuum advance must be
checked and if necessary adjusted.
4. Disconnect the vacuum pipe and connect a vacuum
pump to the unit.
5. Start and run the engine at idle speed and using a
timing light, slowly increase the vacuum and note
the point at which vacuum advance starts and
compare the figure with that given in data.
6. Adjustment of the serrated cam, with the special
tool, one tooth at a time, will alter the point at
which vacuum advance starts.
Check and adjust dwell variation
NOTE: A dwell variation outside the accepted tolerance

- see data - can be caused by a mechanical fault or
wear within the distributor. This may be checked as
follows:
2. Disconnect the vacuum advance, start the engine
and increase the speed to 2000 r.p.m. A variation
outside the tolerance given in data indicates that
the distributor has a mechanical fault which cannot
be rectified by adjustment.
7. f!
the kaiiatioi; is acceptabk, reconnect the
vacuum pipe, start the engine and increase the
engine speed to 2,000 r.p.m. and release the
throttle. Check the dwell variation and if necessary
adjust by tuming the eccentric D post with the
special tool (female D end). Setting the dwell for
minimvin variation may alter the basic setting and
this must be rechecked at idle speed.
16
-I
Ft
MAINTENANCE
RENEW LUCAS CONTACT BREAKER SLIDING
CONTACTS -4-cylinder petrol engine
The contact set should be renewed every 40.000 km
(25,000 miles).
Remove the old contacts
1. Remove the distributor cap.

2. Remove the rotor arm.
3. Remove the retaining screw and lift the contact set
complete from the plate.
4. Press the contact set spring and release the
terminal plate and leads from the spring.
1101
Adjust gap
11. Rotate the crankshaft until the contact heel is on

the highest point of a cam.
12. Adjust the gap by inserting a screwdriver blade
between the V shaped notch and pip and twist the
screwdriver.
13. Insert a 0,35 to 0,40 m m (0.014 to 0.016 in) feeler
gauge between the points and adjust to a sliding fit
and tighten the retaining screw.
14. Fit the rotor arm.
Fit new contacts
5 . Clean the points with petrol to remove the

protective coating.
6. Press the contact spring and fit the terminal plate
with the black lead uppermost.
7. Fit the contact set to the moving plate, ensuring
that the peg, underneath the contact pivot, locates
in the hole in the moving plate.
8. The sliding contact actuating fork must also locate
over the fixed peg.
9. Loosely secure the assembly with the scrcw, plain
and spring washer.
10. Check that the contact leaf spring locates properly
in the insulation shoe.
ST1082M
RENEW DISTRIBUTOR CONTACT SET -V8 engine

Fixed contact type
1. Unclip and remove the distributor cap.
2. Withdraw the rotor arm.
3. Remove the contact breaker spring anchor nut and
lift off:
(a) the top-half of insulation bush
(b) the low tension lead (black)
(c) the capacitor lead (orange)
4. Remove the contact breaker retaining screw, plain
and spring washer and remove contact set
assembly.
5 . Remove the complete insulation bush.
6. Fit the contact breaker set ensuring that the small
post protruding from below the contact set locates
through the hole in the cover plate into the hole in
the end of the vacuum unit actuating lever, secure
with the screw, plain and spring washers.
continued
17
MAINTENANCE
7. Assemble the contact breaker spring insulating
bushes and electrical leads, as illustrated, in the
3,lO-
following sequence:
(a) lower bush
(b) spring
(c) low tension lead
(d) capacitor lead
(e) top bush
and secure with the anchor spring nut.
8. Apply a few drops of engine oil to the distributor
cam lubrication pad.
RR090
Adjust points -both types

9. Turn the engine in the direction of rotation until
the contacts are fully open or the heel of the
contact set is on the highest point of the cam.
10. Using a feeler gauge and the dwell angle adjuster
on the side of the distributor, set the points to a
nominal gap of 0,35 to 0,40 mm (0.014 to 0.016 in).
11. At the earliest opportunity check and adjust the
dwell angle - see data - using spccial turning
equipment.
12. Fit the rotor arm and distributor cap ensuring that
the H.T. pick-up brush moves freely.
Sliding contact type
1. Release the clips and remove the distributor cap.

2. Remove the rotor arm from the cam spindle.
3. Remove the retaining screw and washers and lift
the complete contact breaker assembly from the
moveable plate.
4. Remove t h e nut and plastic bushes from the
terminal post to release the leads and spring.
5. Discard the old contact breaker assembly.
6. Clean the new points with petrol to remove the
protective coating.
7. Connect the leads to the terminal post in the
following sequence:
(a) lower plastic bush
(b) red lead tab
(c) contact breaker spring eye
(d) black lead tab
(e) upper plastic bush
(f) retaining nut.
8. Fit the contact set to the moving plate ensuring that
the two pegs locate in the holes.
1s
ST1083M
--..
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1
L
MAINTENANCE
;:;.,
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CLEAN
AND
DISTRIBUTOR
LUBRICATE
V8
ENGINE
Fixed contact type
1. Remove distributor cap.

2. Remove rotor arm.
3. Lightly smear the cam with clean engine oil.
4. Add a few drops of thin machine oil to lubricate the
cam bearing and distributor shaft.
5. Wipe the inside and outside of the distributor cap
with a soft dry cloth.
6. Ensure that the carbon brush works freely in its
holder.
7. Refit rotor arm and distributor cap
CLEAN
AND
DISTRIBUTOR
LUBRICATE
I10I
DUCELLIER
1. Remove the distributor cover and lift off the rotor

arm and anti-dust shield.
2. Inspect the contact breaker points; if burnt or worn
they should be renewed.
3. Very lightly smear the cam with grease - Shell
Retinax.
4. Lubricate the pressure pad with grease - Shell
Retinax.
5. Add a few drops of oil to the felt pad in the top of
the cam spindle.
6. Turn the engine until the distributor centrifugal
weight pivot post is visible through the cut-out in
the base plate and lubricate the pivot post with a
drop of oil. Repeat for the opposite pivot post.
7. Carefully wipe away all surplus lubricant; and
ensure that the contact breaker points are clean
and dry.
8. Fit the anti-dust shield.
9. Refit the rotor arm, engage the slot in the spindle
and push down firmly.
10. Wipe clean with dry nap-free cloth, the inside and
outside of the distributor cover, particularly
between the electrodes, and fit the distributor
cover.
Sliding contact type

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove distributor cap.

Remove rotor arm.
Lightly smear the cam with clean engine oil.
Add a few drops of thin machine oil to lubricate the
cam bearing and distributor shaft.
Wipe the inside and outside of the distributor cap
with a soft dry cloth.
Ensure that the carbon brush works freely in its
holder.
Lubricate the actuator ramps and contact breaker
heel ribs with Shell Retinax or equivalent grease.
Grease the underside of the heel actuator.
Apply grease to the fixed pin and actuator fork.
Refit rotor arm and distributor cap.
CLEAN V8 ENGINE ELECTRONIC IGNITION

DISTRIBUTOR
80.000 km (48,000 miles)

Remove the distributor cap and rotor arm and wipe
inside with a nap-free cloth.
DO NOT DISTURB the clear plastic insulating cover
which protects the magnetic pick-up module.
RR092
19
MAINTENANCE
CLEAN AND LUBRICATE LUCAS DISTRIBUTOR
1. Clean and lightly grease the cam with Shell Retinax

o r equivalent and remove any surplus lubricant.
2. Using the same grease lubricate the underside of
the heel actuator.
3. Grease the actuator ramps and contact breaker
heel ribs.
4. Apply grease to the fixed pin and the actuator fork.
5. Apply a drop of clean engine oil to the felt pad
underneath the rotor arm.
6. Every 40.000 km (25,000 miles) lubricate the
automatic advance mechanism by injecting one or
two drops of engine oil through the aperture in the
base plate.
7. Wipe the internal and external surfaces of the
distributor cap with clean dry nap-free cloth and fit
the cap to the distributor body.
CHECK AND ADJUST VS ENGINE DISTRIBUTOR

TIMING
Using Electronic Timing Equipment
A pointer on the timing cover and marks on the

crankshaft pulley indicate positions around T.D.C. on
No. 1 cylinder (i.e. front cylinder on left-hand bank).
Refer to 'Engine Tuning data' for appropriate ignition
timing.
Engine speed accuracy during ignition timing is
important. Any variation from the required idle speed,
particularly in an upward direction, will lead to wrongly
set ignition timing.
1. Connect a stroboscopic timing light as instructed by
the manufacturer. The engine is timed on No. 1
cylinder.
2 . Run the engine at idle speed.
3. Position the timing light to illuminate the
crankshaft pulley and scale.
WARNING: Ensure that personnel and equipment
are kept clear of the rotating cooling fan while using
the timing light.
ST1084M
1.
4. If the timing is correct the pulley mark indicated in

the Tuning Data will show. If correct, instruction 5
may be ignored.
5. With the engine still running at idle speed, slacken
the clamp bolt and carefully rotate the distributor
body as required until the correct pulley mark
shows. Turn anticlockwise to advance and
clockwise to retard.
6. Tighten the clamp bolt with the unit in this
position.
3
2
ST
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A,
20
MAINTENANCE
I,
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CLEAN, ADJUST OR RENEW SPARK PLUGS
I10I
Refit or renew spark plugs
1. Withdraw the H.T. leads from the spark plugs by

gripping the shrouds, do not pull on the leads.
2. Using an appropriate plug spanner, remove the
spark plugs.
ST1087M
11. Check that the washers are fitted to the plugs.

12. It is important that only spark plugs specified in
Data section are used for replacements.
13. Incorrect grades of plug may lead to piston overheating and engine failure.
14. Wash new plugs in petrol to remove the protective
coating, then set the electrode gaps to the
appropriate figures given in Engine Tuning data.
15. Fit the plugs and washers to the engine but do not
overtighten.
16. Examine high tension leads, including the coil to
distributor lead, for insulation cracking or
corrosion at end contacts. Fit new leads as
necessary.
17. In addition to correct firing order, high tension
leads must be fitted in correct relation to each
other to avoid cross firing, as illustrated. This is
particularly important on the V8 engine.
First illustration. 4-cylinder engine.
Second illustration. V8 engine.
Clean and set gaps

3. Fit plug in plug cleaning machine.
4. Wobble plug with circular motion while operating
abrasive blast for a maximum of four seconds.
18. When pushing leads on plugs ensure ferrules within

shrouds are firmly seated on plugs.
CAUTION: Excessive abrasive blasting will erode

insulator nose.
. .
5. Change to air blast only and continue to wobble

plug for a minimum of thirty seconds to remove
abrasive grit from plug cavity.
6. Wire-brush plug threads, open gap slightly.
7. Using point file, square off electrode surfaces.
8. Set electrode gap, see Engine Tuning data,
9. Test plugs in accordance with cleaning machine
manufacturers instructions. If satisfactory, refit
plugs in engine.
10. If no machine is available carefully wire brush
electrodes and blow or wash away carbon particles.
ST052
Illustration shows:
A. Dirty o r unsatisfactory electrode
B. Filing plug electrodes

C. A clean plug correctly set
ST051
21
1x1
MAINTENANCE
CLEAN AND TEST HEATER PLUGS

engines
- Diesel
REMOVE THE PLUGS
1. Disconnect the battery.

2. Remove the terminal nut from each heater plug.
3 . Detach the heater plug lead and washer from each
Plug.
4. Remove the heater plugs.
Clean and inspect
CHECK BRAKE FLUID RESERVOIR
1. Check the fluid level in the fluid reservoir by

observing the level in relation to the MIN or
MAX marks on the side of the translucent
reservoir.
2. If the level is below the MAX mark clean the
outside of the filler cap and top-up with new, clean
fluid from a sealed container. Use only fluid
recommended in the General specification data
section. Refit the cap.
5. Remove carbon from base of heater plugs to avoid

the possibility of short circuiting of the element.
Do not sandblast.
6. Examine the element for signs of fracture and
deterioration and the seating for scores. Plugs with
fractures or doubtful elements must be renewed.
Where scoring of the seating may impair the
sealing, the plug should be renewed.
Test and refit
7. Test the plug internal circuit for continuity by

connecting it in circuit with a 12 volt side lamp bulb
and a 12 volt supply. If the bulb does not light an
open circuit is indicated and the heater plug must
be renewed.
ST 1088M
CHECK CLUTCH FLUID RESERVOIR

1. Clean and remove the reservoir cap and observe
the fluid level in relation to the marks on the side of
the reservoir.
2. Top-up if necessary with new, clean fluid from a
sealed container and of a recommended
specification - see General specification data
section. Refit the cap.
STlOPlM
8. Ensure that the terminals are clean and that the

thread at the base of the plug is free from carbon.
9. Fit the heater plugs to the engine. Do not
overtigh ten.
10. Fit the heater plug lead and washer to each plug.
11. Connect the battery.
22
MAINTENANCE
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.
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CHECK POWER STEERING FLUID RESERVOIR
:c
1. Clean and remove the reservoir cap and observe

the fluid level in relation to the mark on the side of
the reservoir.
2. If necessary top-up with a recommended fluid see General specification data section - until the
fluid is 12 mm (95 in) above the filter. Refit the
cap.
CHECK COOLING SYSTEM COOLANT

Refer to the Cooling system section for details of
anti-freeze and inhibitors and to the General
specification data section for anti-freeze protection
quantities.
With a cold engine, the expansion tank should be
approximately half full.
WARNING: Do not remove the filler cap when the

engine is hot because the cooling system is pressurised
and personal scalding could result.
To remove the filler cap, first turn it anti-clockwise

a quarter of a turn and allow all pressure to escape,
before turning further in the same direction to lift it
off.
When replacing the filler cap it is important that it
is tightened down fuily, not just to the first stop.
Failure to tighten the filler cap properly may result
in water loss, with possible damage to the engine
through overheating.
//
BATTERY
Check Specific Gravity
The specific gravity of the electrolyte should be
checked using a battery hydrometer. The readings
should be as follows:
Temperate climate below 26.5C (80F) as
commissioned for service, fully charged 1.270 to 1.290
specific gravity.
As expected during normal service, three-quarter
charged 1.230 to 1.250 specific gravity.
If the specific gravity should read between 1.190 to
1.210, half-charged, the battery must be bench charged
and the electrical equipment in the car should be
checked.
Tropical climate above 26.5C (80F) as commissioned
for service, fully charged 1.210 to 1.230 specific gravity.
As expected during normal service, three-quarter
charge 1.170 to 1.190 specific gravity.
If the specific gravity should read between 1.130 to
1.150, half-charged, the battery must be bench charged
and the electrical equipment on the car should be
checked.
Check and Top-Up Electrolyte Level
1. Wipe all dirt and moisture from the battery top.
2. Remove the filler cover. If necessary add sufficient
distilled water to raise the level to the top of
separators.
Replace the filler plugs or manifold lid.
3 . Avoid the use of a naked light when examining the
ceils.
4. In hot climates it will be necessary to top up the
battery at more frequent intervals.
5. In very cold weather it is essential that the vehicle
is used immediately after topping up, to ensure that
the distilled water is thoroughly mixed with the
electrolyte. Neglect of this precaution may result in
the distilled water freezing and causing damage to
the battery.
Battery terminals
6 . Remove battery terminals, clean, grease and refit.
7 . Replace terminal screw; do not overtighten. Do
not use the screw for pulling down the terminal.
8. Do NOT disconnect the battery cables while the
engine is running or damage to alternator
semiconductor devices may occur. It 1s also
inadvisable to break or make any connection in the
alternator charging and control circuits while the
engine is running.
9. It is essential to observe the polarity of connections
to the battery, alternator and regulator, as any
incorrect connections made when reconnecting
cables may cause irreparable damage to the
semiconducto r devices.
IMPORTANT NOTE: If a new battery is fitted to the
vehicle, it should be the same type as fitted to the vehicle
when new. Alternative batteries may vary in size and
terminal positions and this could be a possible fire
hazard if the terminals or leads come into contact with
the battery clamp assembly. When fitting a new battery
ensure that the terminals and leads are clear of the
battery clamp assembly.
23
MAINTENANCE
REMEW BRAKE SERVO FILTER
1. Remove the nuts securing the master cylinder to
the servo.
2. Release the clip retaining the brake pipe to the
clutch pipe.
3. Separate the master cylinder from the servo.
4. Disconnect the vacuum hose from the servo.
5. Disconnect the Lucars from the stop lamp switch at
the rear of the pedal box.
6 . Remove the blanking grommets from the pedal
box.
7. Remove the split pin from the clevis and withdraw
the clevis pin and washer.
ST1533M
.-
' F "
9. Pull back the dust cover.

10. Release the end-cap.
11. Cut the filters to remove them from the shaft.
%L.
ST1485M
8. Remove the four nuts securing the servo to the

pedal box and remove the servo.
24
12. Clean the filter seating and fit the new filters noting
that they must be cut to fit over the shaft.
13. Fit the end-cap and dust cover and refit the servo
and master cylinder to the vehicle reversing the
removal procedure. Use a new split pin to secure
the clevis.
14. Test the brakes.
6."'*
MAINTENANCE
:.'
..
-j
.;:y
I10I
ENGINE SLOW RUNNING -2.5 Diesel

1. Using a suitable tachometer, check the engine slow
running adjustment 'see Engine tuning data'. If
adjustment is necessary slacken the locknut and
turn the control screw clockwise to increase the
revolutions and anti-clockwise to decrease the
engine speed. Tighten the locknut, increase the
engine speed for a few seconds then re-check the
slow running.
ST1425M
2. If a tachometer is not available adjust the control

screw until the slowest speed is obtained consistent
with smooth and even running.
NOTE: The slow running control is the only
permitted adjustment in service. Any additional
adjustments required must only be carried out by
authorised C.A.V. agents.
25

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TABLE OF' CONTENTS

Torque Wrench Settings..

Recommended Lubricants, Fluids and Capacities.. .....................................................

Fuel System (including Fuel Injection) .....................................................................

BOOK ONE CONTENTS

- Repairsand replacement parts

of vehicle identification numbers

GENERAL SPECIFICATION DATA

ENGINE TUNING DATA

-V8 engine tuning data

TORQUE WRENCH SETINGS

Book One Contents (contd)

GENERAL FITTING INSTRUCTIONS

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

REPAIRS AND REPLACEMENTS

FUEL HANDLING PRECAUTIONS

NO O N E SHOULD BE PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL/

FUEL TANK DRAINING

FUEL TANK REMOVAL

FUEL TANK REPAIR

Special Service Tools

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS

The Vehicle Identification Number and the

ENGINE SERIAL NUMBER

The 4 cylinder engine number is stamped on a

ENGINE SERIAL NUMBER -VS ENGINE

The V8 engine serial number is stamped on a cast pad

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS

TRANSFER GEARBOX LT230T - 4 CYLINDER

Stamped on top of the left-hand axle tube.

Stamped on rear of left-hand axle tube.

Stamped on a pad on the right-hand side of the gearbox

Stamped on the right-hand side of the front bearing

TRANSFER GEARBOX LT230R

Stamped on the casing on the left-hand side of the

GENERAL SPECIFICATION DATA

58,409 - 58,422 mm (2.2996 - 2.3001 in)

Horizontally split big end, pIain small end

Big end bearings

72,67 - 72,79 mm (2.861 - 2.866 in)

0,018 - 0,033 mm (0.0007 - 0.0013 in)

GENERAL SPECIFICATION DATA

0,025 - 0,066 mm (0.0010 - 0.0026 in)

Wet sump, pressure fed

Oil pressure reIief valve

Oil filter by-pass valve

116,59 - 117,35 mm (4.590 - 4.620 in)

39,75 - 40,OO mm (1.565 - 1.575 in)

GENERAL SPECIFICATION DATA

2.25 LITRE PETROL ENGINE

90,47 mm (3.562 in)

63,487 - 63.500 mm (2.4995 - 2.500 in)

Horizontally split big end, plain small end

Big end bearings

Steel shell, copper-lead lined

Aluminium alloy, flat top

GENERAL SPECIFICATION DATA