1970-1985 Range Rover Five Speed Manual Gearbox & Automatic Gearbox Repair Operation Manual – PDF DOWNLOAD
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1970-1985 Range Rover Five Speed Manual Gearbox & Automatic Gearbox Repair Operation Manual – PDF DOWNLOAD
Language : English
Pages : 696
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1970-1985 Range Rover Five Speed Manual Gearbox & Automatic Gearbox Repair Operation Manual – PDF DOWNLOAD
INTRODUCПON:
The purpose of this cumulative manual is to assist skilled mechanics in the efficient repair and maintenance of RangeRover
vehicles from their inception. The procedures detailed, carried out in the sequence given and using the
appropriate service tools, will еnаЫе the operations to Ье completed in the tirne stated in the Repair Operation Times.
Indexing:
- For convenience, this Manual is divided into а number of divisions. А contents page listing the titles and reference
numbers of the various divisions is shown opposite. - А list of the operations within each of the divisions appears in alphabetical order on the contents page preceding each
of the divisions.
Operation Numbering:
- Each operation is followed Ьу the number allocated to it in а master index. The number consists of six digits arranged
in three pairs. - The master index of operations has been compiled for universal application to vehicles manufactured Ьу BL Umited
and therefore continuity of the numbering sequence is not maintained throughout the Manual. То assist with locating
information, each division of the Manual is preceded Ьу а contents page listing the operations in alphabetical order. - Each instruction within an operation has а sequence number and, to complete the operation in the minimum time it is essential that these instructions are performed in numerical sequence commencing at 1 unless otherwise stated. Where applicaЫe the sequence numbers identify the components in the appropriate illustration.
- Where performance of an operation requires the use of service tool, the tool number is quoted under the operation
heading and is repeated in, or following the instruction involving its use.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
1970-1985 Range Rover Five Speed Manual Gearbox & Automatic Gearbox Repair Operation Manual – PDF DOWNLOAD
Repair Operation Manual…………………………………………….. 1
Contents………………………………………………………. 3
Introduction…………………………………………………… 4
Safety………………………………………………………… 5
Abbreviations and Symbols……………………………………….. 6
General Specification Data………………………………………. 7
Engine Tuning Data……………………………………………… 13
Torque Wrench Settings………………………………………….. 19
General Fitting Instructions…………………………………….. 21
Recommended Lubricants, Fuel and Fluids – capacities……………….. 28
Maintenance……………………………………………………. 30
Engine……………………………………………………………. 58
Camshaft – remove and refit……………………………………… 61
Connecting Rods and Pistons……………………………………… 62
remove and refit……………………………………………. 62
overhaul…………………………………………………… 63
Crankshaft…………………………………………………….. 70
remove and refit……………………………………………. 70
overhaul…………………………………………………… 74
Engine Bearing – remove and refit…………………………….. 90
Cylinder………………………………………………………. 78
Heads – remove and refit…………………………………….. 78
Heads – overhaul……………………………………………. 81
Pressures – check…………………………………………… 77
Engine Assembly – remove and refit……………………………….. 86
Flywheel………………………………………………………. 88
remove and refit……………………………………………. 88
overhaul…………………………………………………… 88
Starter Ring Gear – remove and refit………………………….. 89
Oil…………………………………………………………… 90
Filter Assembly, external – remove and refit…………………… 90
Pump – remove and refit……………………………………… 91
Pump – overhaul…………………………………………….. 92
Sump – remove and refit……………………………………… 93
Timing………………………………………………………… 96
Chain and Gears – remove and refit……………………………. 96
Gear Covers………………………………………………… 94
Valve Gear – remove and refit……………………………………. 83
Emission and Evaporative Control…………………………………….. 98
Air Injection System – description………………………………..101
Air Manifold – remove and refit…………………………………..103
Air Pump (Australian)……………………………………………101
description…………………………………………………101
remove and refit…………………………………………….102
Air Pump Drive Belt (Australian)………………………………….102
check and adjust tension……………………………………..102
remove and refit…………………………………………….103
Check Valve/Pulse Air Valve………………………………………104
check operation……………………………………………..104
remove and refit…………………………………………….104
Diverter and Relief Valve (Australian)…………………………….105
check operation……………………………………………..105
remove and refit…………………………………………….105
Relief Valve……………………………………………………102
check operation……………………………………………..102
remove and refit…………………………………………….102
Air Intake Temperature Control System – description…………………106
Control Flap Valve………………………………………………106
check operation……………………………………………..106
remove and refit…………………………………………….108
Hot Air Box – remove and refit……………………………………108
Crankcase Breathing System – description………………………….. 99
Engine Breather Filter – remove and refit…………………………. 99
Engine Flame Trap – remove and refit………………………………100
Evaporative Loss Control System (Australian) – description………….100
Adsorption Canister (Australian) – remove and refit…………………100
Exhaust Gas Recirculation (E.G.R.) System (Australian) – description….109
Valve (Australian) ……………………………………………..109
check operation……………………………………………..109
remove and refit…………………………………………….109
Fuel System………………………………………………………..110
Air Cleaner…………………………………………………….113
remove and refit…………………………………………….113
renew elements………………………………………………114
Carburetters……………………………………………………128
Auto Choke – remove and refit…………………………………128
Deceleration (Poppet Valve) – remove and refit………………….131
description…………………………………………………115
Diaphragm – remove and refit………………………………….128
Float Chamber Levels – check and adjust………………………..127
Float Chamber Needle Valve – check and adjust…………………..127
overhaul……………………………………………………122
remove and refit…………………………………………….121
Temperature Compensator – remove and refit……………………..131
Throttle (Butterfly) disc – remove and refit……………………132
tune and adjust……………………………………………..118
Choke Control Cable – remove and refit…………………………….133
Fuel Line Filter – remove and refit……………………………….134
Fuel Main Filter………………………………………………..134
remove and refit…………………………………………….134
Element – remove and refit……………………………………134
Fuel Pipes …………………………………………………….135
Main Line, Tank and Section – remove and refit………………….135
Main Line, Centre Section…………………………………….135
Main Line, Carburetter End Section – remove and refit……………135
Spill Return – remove and refit……………………………….135
Fuel Pump………………………………………………………136
remove and refit…………………………………………….136
overhaul……………………………………………………136
Fuel Tank – remove and refit……………………………………..139
Thermostat Switch – remove and refit………………………………130
Throttle Cable – remove and refit…………………………………132
Throttle Linkage – remove and refit……………………………….133
Throttle Pedal – remove and refit…………………………………132
Cooling System……………………………………………………..140
Coolant – drain and refill……………………………………….142
Expansion Tank – remove and refit…………………………………144
Fan Belt……………………………………………………….144
check and adjust…………………………………………….144
remove and refit…………………………………………….144
Fan Blades and Pulley – remove and refit…………………………..145
Fan Blades – remove and refit…………………………………….145
Fan Cowl – remove and refit………………………………………145
Radiator Block – remove and refit…………………………………146
Thermostat – remove and refit…………………………………….147
Water Pump……………………………………………………..148
remove and refit…………………………………………….148
overhaul……………………………………………………149
Manifold and Exhaust System………………………………………….150
Exhaust Manifold………………………………………………..155
Left Hand – remove and refit………………………………….155
Right Hand – remove and refit…………………………………155
Exhaust System………………………………………………….152
Front Pipe, left hand – remove and refit……………………….152
Front Pipe, right hand – remove and refit………………………152
Silencer – remove and refit…………………………………..152
Intermediate Pipe – remove and refit…………………………..152
remove and refit…………………………………………….152
tail pipe – remove and refit………………………………….152
Induction Manifold – remove and refit……………………………..153
Clutch…………………………………………………………….156
Clutch Assembly…………………………………………………157
remove and refit…………………………………………….157
overhaul……………………………………………………158
Clutch Pedal – remove and refit…………………………………..163
Hydraulic System – bleed…………………………………………159
Master Cylinder…………………………………………………160
remove and refit…………………………………………….160
overhaul……………………………………………………161
Release Bearing Assembly…………………………………………162
remove and refit…………………………………………….162
Slave Cylinder………………………………………………….164
remove and refit…………………………………………….164
overhaul……………………………………………………165
Gearbox……………………………………………………………166
Main Gearbox……………………………………………………166
Bell Housing – remove and refit……………………………….170
Bearing Plate – remove and refit………………………………171
Front Cover and Oil Pump Assembly……………………………..172
remove and refit…………………………………………172
overhaul………………………………………………..173
Gearbox – remove and refit……………………………………176
Gearchange Selectors – remove and refit………………………..174
Layshaft……………………………………………………184
remove and refit…………………………………………184
Bearings – remove and refit……………………………….185
Mainshaft Assembly – remove and refit………………………….187
Mainshaft Assembly – overhaul…………………………………190
Primary Pinion – remove and refit……………………………..184
Reverse Idler Gear and Shaft – remove and refit…………………183
Reverse Light Switch – remove and refit………………………..196
Transfer Gearbox………………………………………………..166
Differential Lock Actuator Switch – remove and refit…………….196
Differential Unit Assembly …………………………………..202
remove and refit…………………………………………202
overhaul………………………………………………..203
Front Output Shaft and Housing………………………………..169
remove and refit…………………………………………169
overhaul………………………………………………..169
Front Output Shaft Oil Seal – remove and refit………………….192
Gear Lever and Cross Shaft – remove and refit…………………..197
Gear Selectors and Shaft – remove and refit…………………….198
Intermediate Gears Assembly – remove and refit………………….199
Mainshaft Transfer Gear – remove and refit……………………..189
Rear Output Shaft Oil Seal – remove and refit…………………..192
Speedometer Drive Housing…………………………………….193
remove and refit…………………………………………193
overhaul………………………………………………..194
Differential Lock Actuator Assembly……………………………205
remove and refit…………………………………………205
overhaul………………………………………………..205
Front Propeller Shaft……………………………………………….206
overhaul……………………………………………………….209
remove and refit………………………………………………..208
Rear Propeller Shaft………………………………………………..206
remove and refit………………………………………………..208
overhaul……………………………………………………….209
Rear Axle and Final Drive……………………………………………212
Axle Shaft – remove and refit…………………………………….213
Differential Assembly……………………………………………213
remove and refit…………………………………………….213
overhaul……………………………………………………214
Pinion Oil Seal – remove and refit………………………………..220
Rear Axle Assembly – remove and refit……………………………..221
Front Axle and Final Drive…………………………………………..222
Axle Case Oil Seal – remove and refit……………………………..225
Differential Assembly……………………………………………223
remove and refit…………………………………………….223
overhaul……………………………………………………214
Front Axle – remove and refit…………………………………….224
Half Shaft – remove and refit…………………………………….225
Pinion Oil Seal – remove and refit………………………………..220
Steering…………………………………………………………..226
Drag Link………………………………………………………261
remove and refit…………………………………………….261
Ends – remove and refit………………………………………261
Drop Arm – remove and refit………………………………………259
Front Wheel Alignment – check and adjust…………………………..263
Lock Stops – check and adjust…………………………………….263
Manual Steering Box……………………………………………..253
adjust……………………………………………………..253
remove and refit…………………………………………….250
overhaul……………………………………………………251
Power Steering Box………………………………………………239
adjust……………………………………………………..239
remove and refit…………………………………………….227
overhaul……………………………………………………229
Power Steering Fluid Reservoir – remove and refit…………………..244
Power Steering Pump……………………………………………..246
remove and refit…………………………………………….246
overhaul……………………………………………………248
Drive Belt – adjust………………………………………….245
Drive Belt – remove and refit…………………………………245
Power Steering System……………………………………………243
bleed………………………………………………………243
test……………………………………………………….240
Steering Column…………………………………………………254
remove and refit…………………………………………….254
overhaul……………………………………………………255
Steering Column Lock and Ignition/Starter Switch……………………258
remove and refit…………………………………………….258
Steering Damper – remove and refit………………………………..254
Steering Wheel – remove and refit…………………………………262
Track Rod………………………………………………………260
remove and refit…………………………………………….260
Linkage – remove and refit……………………………………260
Universal Joints and Coupling Shaft – remove and refit………………257
Front Suspension……………………………………………………264
Bump Stop – remove and refit……………………………………..275
Hub Assembly …………………………………………………..270
remove and refit…………………………………………….270
overhaul……………………………………………………272
Hub Bearing End Float – check and adjust…………………………..273
Hub Stub Axle…………………………………………………..274
remove and refit…………………………………………….274
overhaul……………………………………………………274
Panhard Rod – remove and refit……………………………………265
Radius Arm – remove and refit…………………………………….265
Road Spring – remove and refit……………………………………269
Shock Absorber – remove and refit…………………………………275
Swivel Pin Housing………………………………………………266
remove and refit…………………………………………….266
overhaul……………………………………………………267
Rear Suspension…………………………………………………….276
Bump Stop – remove and refit……………………………………..284
Hub……………………………………………………………278
remove and refit…………………………………………….278
overhaul……………………………………………………279
Hub Bearing End-Float……………………………………………279
check and adjust…………………………………………….279
Hub Bearing Sleeve (stub-axle)……………………………………280
remove and refit…………………………………………….280
overhaul……………………………………………………280
Road Spring – remove and refit……………………………………281
Shock Absorber – remove and refit…………………………………281
Self Levelling Unit – remove and refit…………………………….282
Self Levelling Unit Ball Joints – remove and refit………………….283
Suspension Link, Lower ………………………………………….285
Bush – remove and refit………………………………………285
remove and refit…………………………………………….285
Suspension Link, Upper…………………………………………..284
Bush, remove and refit……………………………………….284
remove and refit…………………………………………….284
Brakes…………………………………………………………….286
Bleed Hydraulic System…………………………………………..293
Calipers……………………………………………………….305
Front – remove and refit……………………………………..305
Front – overhaul…………………………………………….306
Rear – remove and refit………………………………………305
Rear – overhaul……………………………………………..308
Description…………………………………………………….287
Discs………………………………………………………….288
Front – remove and refit……………………………………..288
Rear – remove and refit………………………………………288
Fluid Reservoir – remove and refit………………………………..297
Hoses………………………………………………………….290
Front Left Hand – remove and refit…………………………….290
Front Right Hand – remove and refit……………………………290
Intermediate – remove and refit……………………………….290
Master Cylinder – tandem…………………………………………294
remove and refit…………………………………………….294
overhaul……………………………………………………295
Pads…………………………………………………………..299
front – remove and refit……………………………………..299
rear – remove and refit………………………………………300
Pedal Assembly………………………………………………….297
remove and refit…………………………………………….297
overhaul……………………………………………………298
Pipes – remove and refit…………………………………………290
feed to front left hand hose connector…………………………290
feed to front right hand hose connector………………………..290
feed to front left hand caliper……………………………….290
feed to front right hand caliper………………………………290
feed to rear left hand caliper………………………………..290
feed to rear right hand caliper……………………………….290
feed to two-way connector…………………………………….290
feed to intermediate hose…………………………………….290
feed to brake failure switch, secondary section…………………290
feed to brake failure switch, primary section…………………..290
feed – pressure reducing valve to rear brake hose……………….290
transfer pipe – pressure reducing valve………………………..290
Pressure Reducing Valve – remove and refit…………………………294
Servo Assembly – remove and refit…………………………………304
Switch-Brake Failure…………………………………………….291
remove and refit…………………………………………….291
overhaul……………………………………………………292
Transmission Brake………………………………………………302
adjust……………………………………………………..302
Assembly – remove and refit…………………………………..302
Shoes – remove and refit……………………………………..302
Lever and Linkage – remove and refit…………………………..301
Lever – overhaul…………………………………………….301
Wheels and Tyres Operations………………………………………….310
Tyres………………………………………………………….311
pressure check………………………………………………311
remove and refit…………………………………………….311
Wheels and Tyres – balance……………………………………….312
Wheels – remove and refit………………………………………..313
Body Operations…………………………………………………….316
Body…………………………………………………………..317
Rear Corner Panel, left hand – remove and refit…………………323
Rear Corner Panel, right hand – remove and refit………………..323
Rear Quarter Panel, left hand – remove and refit ……………….324
Rear Quarter Panel, right hand – remove and refit……………….324
Side Glass Front – remove and refit……………………………349
Side Glass Rear – remove and refit…………………………….349
Side, Wheelarch and Inner Floor, left hand – remove and refit…….321
Side, Wheelarch and Inner Floor, righ hand – remove and refit…….321
Bonnet – remove and refit………………………………………..330
Chassis Frame – alignment check…………………………………..320
Dash Panel Assembly – remove and refit…………………………….329
Door, front…………………………………………………….330
Door – remove and refit………………………………………330
Glass – remove and refit……………………………………..333
Glass Regulator – remove and refit…………………………….335
Lock – remove and refit………………………………………337
Private Lock – remove and refit……………………………….341
Quarter Vent – remove and refit……………………………….335
Door, rear……………………………………………………..331
Door – remove and refit………………………………………331
Check Strap…………………………………………………342
Glass – remove and refit……………………………………..334
Glass Regulator – remove and refit…………………………….336
Hinges – remove and refit…………………………………….332
Lock – remove and refit………………………………………338
Facia………………………………………………………….330
Console Unit – remove and refit……………………………….330
Glove Box – remove and refit………………………………….345
Lower Panel – remove and refit………………………………..343
Top Rail – remove and refit…………………………………..344
Front Decker Panel – remove and refit……………………………..328
Front Floor – remove and refit……………………………………322
Headling ………………………………………………………345
Front Section – remove and refit………………………………345
Rear Section – remove and refit……………………………….345
Roof Panel – remove and refit…………………………………….322
Seat…………………………………………………………..346
Base – remove and refit………………………………………346
Front Seats – remove and refit………………………………..346
Tailgate……………………………………………………….327
Frame – remove and refit……………………………………..327
Glass – remove and refit……………………………………..348
Lock, lower – adjust…………………………………………341
Lock, lower – remove and refit………………………………..341
Lock, upper – remove and refit………………………………..340
Lower – remove and refit……………………………………..332
Stays, upper – remove and refit……………………………….343
Upper – remove and refit……………………………………..332
Windscreen Glass – remove and refit……………………………….348
Wings …………………………………………………………325
Front – remove and refit……………………………………..325
Front Valance, left hand – remove and refit…………………….347
Front Valance, right hand – remove and refit……………………347
Rear, left hand – remove and refit…………………………….326
Rear, right hand – remove and refit……………………………326
Paintwork………………………………………………………….350
General Information……………………………………………..351
Heating and Ventilation……………………………………………..352
Fan……………………………………………………………354
Motor – remove and refit……………………………………..354
Motor Resistance Unit – remove and refit……………………….355
Heater…………………………………………………………353
Controls – remove and refit…………………………………..353
Radiator – remove and refit…………………………………..355
Unit – remove and refit………………………………………353
Air Conditioning……………………………………………………356
Air Conditioning System………………………………………….389
charge……………………………………………………..389
depressurise………………………………………………..384
evacuate……………………………………………………386
leak test…………………………………………………..390
pressure test……………………………………………….391
sweep………………………………………………………387
test……………………………………………………….392
Blower Assembly – remove and refit………………………………..379
Charging and Testing Equipment – fit and remove…………………….382
Compressor……………………………………………………..373
remove and refit…………………………………………….373
drive belt adjust……………………………………………369
drive clutch – remove and refit……………………………….369
oil level -check…………………………………………….371
Condenser – twin fan system – remove and refit……………………..376
Condenser and Fan Assembly – single fan system – remove and refit…….377
Condenser Fan Motor – remove and refit…………………………….375
Condenser Fans and Motors – twin fan system – remove and refit……….375
Description and General Service Information………………………..357
Evaporator – remove and refit…………………………………….379
Expansion Valve – remove and refit………………………………..379
Hose – Compressor to Evaporator – remove and refit………………….379
Hose – Receiver/Drier to Evaporator – remove and refit………………379
Liquid Receiver/Drier – remove and refit…………………………..378
Wipers and Washers………………………………………………….394
Description…………………………………………………….395
Headlamp Washer…………………………………………………403
Jet – remove and refit……………………………………….403
Pump – remove and refit………………………………………403
Reservoir – remove and refit………………………………….396
Switch – remove and refit…………………………………….403
Tube – remove and refit………………………………………403
Headlamp Wiper………………………………………………….404
Arm – remove and refit……………………………………….404
Blade – remove and refit……………………………………..404
Motor – remove and refit……………………………………..404
Motor – overhaul…………………………………………….405
Rack – remove and refit………………………………………405
Switch – remove and refit…………………………………….403
Wheelbox and Rack Tube – remove and refit………………………405
Tailgate Glass Washer……………………………………………406
Jet – remove and refit……………………………………….406
Pump – remove and refit………………………………………396
Reservoir – remove and refit………………………………….396
Switch – remove and refit…………………………………….407
Tailgate Glass Wiper…………………………………………….394
Arm – remove and refit……………………………………….398
Blade – remove and refit……………………………………..398
Motor – remove and refit……………………………………..408
Motor – overhaul…………………………………………….409
Rack – remove and refit………………………………………411
Switch – remove and refit…………………………………….407
Wheelbox – remove and refit…………………………………..411
Windscreen Washer……………………………………………….397
Jet – remove and refit……………………………………….397
Pump – remove and refit………………………………………397
Reservoir – remove and refit………………………………….396
Tubes – remove and refit……………………………………..397
Windscreen Wiper………………………………………………..398
Arm – remove and refit……………………………………….398
Blade – remove and refit……………………………………..398
Motor, Linkage and Wheelboxes – remove and refit………………..398
Motor – overhaul…………………………………………….399
Switch – remove and refit…………………………………….394
Electrical Equipment………………………………………………..412
Alternator……………………………………………………..426
remove and refit…………………………………………….426
overhaul……………………………………………………428
test……………………………………………………….432
Battery – remove and refit……………………………………….457
Cigar Lighter – remove and refit………………………………….485
Distributor…………………………………………………….459
remove and refit…………………………………………….459
overhaul……………………………………………………462
Flasher Unit – remove and refit…………………………………..469
Fuse Box – remove and refit………………………………………485
Hazard Flasher Unit – remove and refit…………………………….469
Horns – remove and refit…………………………………………457
Ignition Coil – remove and refit………………………………….463
Inspection Sockets – remove and refit……………………………..467
Lamps………………………………………………………….468
remove and refit…………………………………………….468
Differential Lock Illumination………………………………..468
Headlamp Assembly……………………………………………464
Number Plate Illumination…………………………………….466
Panel Illumination…………………………………………..467
Reverse…………………………………………………….465
Roof……………………………………………………….466
Tail, Stop and Flasher Assembly, LH……………………………465
Tail, Stop and Flasher Assembly, RH……………………………465
Warning Light Cluster………………………………………..468
Reflectors – remove and refit…………………………………….465
Spark Plugs – remove, clean, adjust and refit………………………458
Starter Motor…………………………………………………..470
remove and refit…………………………………………….470
overhaul……………………………………………………472
Relay – remove and refit……………………………………..469
Solenoid – remove and refit…………………………………..470
Switches – remove and refit………………………………………479
choke warning light………………………………………….484
combined direction indicator/headlight/horn…………………….485
door pillar…………………………………………………480
handbrake warning light………………………………………483
hazard warning………………………………………………483
heated rear window…………………………………………..482
ignition/starter…………………………………………….479
lighting……………………………………………………479
panel light…………………………………………………480
reverse light……………………………………………….481
roof lamp…………………………………………………..482
spot/fog light………………………………………………481
stop light………………………………………………….484
windscreen wiper/washer………………………………………482
Instruments………………………………………………………..486
Ammeter – remove and refit……………………………………….487
Battery Voltmeter – remove and refit………………………………487
Clock – remove and refit…………………………………………487
Coolant Temperature Gauge – remove and refit……………………….489
Coolant Temperature Transmitter – remove and refit………………….489
Fuel Gauge – remove and refit…………………………………….490
Fuel Gauge Tank Unit – remove and refit……………………………491
Instrument Housing – remove and refit……………………………..487
Instrument Printed Circuit – remove and refit………………………488
Oil Pressure Gauge – remove and refit……………………………..487
Oil Pressure Warning Switch – remove and refit……………………..488
Oil Temperature Gauge – remove and refit…………………………..487
Speedometer – remove and refit……………………………………492
Speedometer Angle Drive – Instrument End – remove and refit………….493
Speedometer Cable Assembly – remove and refit………………………493
Speedometer Trip Reset – remove and refit………………………….492
Voltage Stabilizer – remove and refit……………………………..488
Optional Equipment………………………………………………….494
Centre Power Take Off……………………………………………495
Split Charging Facility………………………………………….496
Third Axle……………………………………………………..497
Trailer Fittings………………………………………………..498
Winch – Front – Capstan………………………………………….499
Winch – Front – Electric…………………………………………500
Service Tools List………………………………………………….501
Service Tools…………………………………………………..502
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