Land Rover Range Rover Classic Workshop 1995 Rover Manual

30MANIFOLD AND EXHAUST SYSTEM RANGE ROVER
4
REPAIR EXHAUST MANIFOLD - Tdi
Service repair no - 30.15.10
Remove
1.Disconnect battery negative lead.
2.Remove heat shield from rear of air intake
manifold.
3.Release dip stick tube from cylinder block.
4.Disconnect the intake hose from the manifold.
5.Remove the two bolts and two nuts securing the
intake manifold to the cylinder head and
withdraw the inlet manifold.
6.Remove air filter inlet pipe to turbo unit.
7.Remove intercooler pipe from turbo to...

MANIFOLD AND EXHAUST SYSTEM
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
MANIFOLDS AND EXHAUSTS - Mpi
Inlet manifold nuts and bolts 25......................................................................
Fuel pipe to fuel rail 10....................................................................................
Exhaust manifold nuts...

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit fitted with the manual transmission,
comprises a single dry plate friction disc and
diaphragm spring clutch unit, secured to the engine
flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder 12 and a slave cylinder 13 attached to the
transmission bell housing.
1. Crankshaft and flywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts (9) for diaphragm spring
7. Bearing...

33CLUTCH
2
DESCRIPTION AND OPERATION When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever 10, bearing 9, to the inner fingers of the
diaphragm spring 4.
The diaphragm spring 4 pivots on the bearing rings 7
and fulcrum posts 6 causing the pressure plate 5 to
release the clamping force on the friction plate and
linings 2.As the the clamping force is removed from the friction
plate 2, the plate slides on the splines of the primary
shaft 15 and...

CLUTCH
1
FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS
For the clutch to operate correctly as described and
illustrated in the Description and Operation, it is
important the following conditions are satisfied:-
A. The primary shaft 15 must be free in the
crankshaft spigot bush 17.
B. The friction plate 2 must be able to slide easily
on the splines on the primary shaft 15, to a
position where it does not contact either the
flywheel or the pressure plate.
C. The friction plate must not be distorted or the...

33CLUTCH
2
FAULT DIAGNOSIS FAULT/SYMPTOM CHART
Symptoms
Slip Spin/Drag Judder/Fierce Fault Item
* * * Worn or oil on clutch linings 2
* * * Mechanical damage45678
* * Distorted clutch plate 2
* Failed or air in hydraulic system 12 13
* * Primary shaft tight fit in crankshaft bush 15 17
* Clutch splines sticking 2 15
* Weak clutch plate springs or insecure/worn
engine/gearbox mountings6
* Insecure/worn propeller shafts
* Insecure/worn suspension components/rubber
bushes
For items refered to in this...

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01
Clutch pressure plate
Renew pressure plate if diaphragm spring fingers are
worn or if pressure plate shows signs of wear, cracks
or burning.
Clutch driven plate
Renew driven plate if centre hub splines are worn or if
lining is contaminated, burned or unevenly worn.
Service tools:
Clutch centralising tool
LRT-12-001 - V8
LRT-12-040 - Tdi
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Mark position of clutch cover to...

33CLUTCH
2
REPAIR BLEED HYDRAULIC SYSTEM
Service repair no - 33.15.01
Procedure
NOTE: During bleed procedure, keep fluid
reservoir topped up to avoid introducing
air to system. For hydraulic fluid
recommendations.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Recommended
Lubricants and Fluids
1.Attach suitable tubing to slave cylinder bleed
screw.
2.Place free end of tube in a glass jar containing
clutch fluid.
3.Loosen bleed screw.
4.Pump clutch pedal, pausing at end of each
stroke, until fluid...

CLUTCH
3
REPAIR Refit
7.Fit the master cylinder and fixings.
8.Fit push-rod to pedal and retain with clevis pin
and washer.
9.Raise fasica fuse box panel.
10.Fit fluid pipe to master cylinder.
11.Bleed system.
See Bleed Hydraulic System
RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Remove clutch slave cylinder.See Slave
Cylinder
3.Withdraw retainer staple.
4.Withdraw bearing and sleeve. If required, press
bearing off...

33CLUTCH
4
REPAIR SLAVE CYLINDER
Service repair no - 33.35.01
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Evacuate clutch system fluid at slave cylinder
bleed valve.
2.Disconnect fluid pipe.
3.Remove two securing bolts and withdraw slave
cylinder and backing plate.
4.If dust cover is not withdrawn with slave cylinder,
withdraw it from bell housing.
Refit
5.Withdraw dust cover and backing plate from
slave cylinder.
6.Coat both sides of backing plate with...