Land Rover Range Rover Classic Workshop 1995 Rover Manual
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01INTRODUCTION
12
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate located under the bonnet [hood] riveted to
the front of the engine compartment.
Vehicle Identification Number Plate (UK, Australia,
R.O.W., Europe)
A.Build date (Australia). Type approval
B.VIN (17 digits)
C.Maximum permitted laden weight for vehicle
D.Maximum vehicle and trailer weight
E.Maximum road weight-front axle
F.Maximum road...](http://img.usermanuals.tech/thumb/2848/48615/w64_range-rover-classic-workshop-manual-1995-rover-13.png "Page 14
01INTRODUCTION
12
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate located under the bonnet [hood] riveted to
the front of the engine compartment.
Vehicle Identification Number Plate (UK, Australia,
R.O.W., Europe)
A.Build date (Australia). Type approval
B.VIN (17 digits)
C.Maximum permitted laden weight for vehicle
D.Maximum vehicle and trailer weight
E.Maximum road weight-front axle
F.Maximum road...")
INTRODUCTION 9 INFORMATION D.Connect other end of second jumper cable to a good earth point on the engine,NOT TO NEGATIVE TERMINAL OF DISCHARGED BATTERY.Keep jumper lead away from moving parts, pulleys, drive belts and fan blade assembly. WARNING: Making final cable connection could cause an electrical arc which if made near battery could cause an explosion. 3.If booster battery is installed in another vehicle, start engine and allow to idle. 4.Start engine of vehicle with discharged battery, following starting procedure in Owners Manual. CAUTION: If vehicle fails to start within a maximum time of 12 seconds, switch ignition off and investigate cause. Failing to follow this instruction could result in irrepairable damage to catalysts. 5.Remove negative (-) jumper cable from the engine and then terminal of booster battery. 6.Remove positive (+) jumper cable from positive terminals of booster battery and discharged battery.
01INTRODUCTION 10 INFORMATION ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL Across flats (bolt size) AF............................................ After bottom dead centre ABDC................................... After top dead centre ATDC......................................... Alternating current a.c.................................................. Ampere amp................................................................ Ampere hour amp hr.................................................... Before bottom dead centre BBDC................................ Before top dead centre BTDC...................................... Bottom dead centre BDC............................................. Brake horse power bhp................................................ British Standards BS.................................................... Carbon monoxide CO.................................................. Centimetre cm............................................................. Centigrade (Celsius) C................................................ Cubic centimetre cm 3................................................... Cubic inch in3............................................................... Degree (angle) deg or° ............................................... Degree (temperature) deg or° ..................................... Diameter dia................................................................ Direct current d.c.......................................................... Electronic Control Unit ECU........................................ Electronic Fuel Injection EFI........................................ Fahrenheit F................................................................. Feet ft........................................................................... Feet per minute ft/min.................................................. Fifth 5th........................................................................ First 1st........................................................................ Fluid ounce fl oz.......................................................... Foot pounds (torque) lbf ft............................................ Fourth 4th..................................................................... Gramme (force) gf........................................................ Gramme (mass) g........................................................ Gallons gal................................................................... Gallons (US) US gal..................................................... High tension (electrical) H.T......................................... Internal diameter I.D.................................................... Inches of mercury in. Hg.............................................. Inches in...................................................................... Kilogramme (force) kgf................................................. Kilogramme (mass.) kg................................................ Kilogramme centimetre (torque) kgf.cm....................... Kilogramme per square millimetre kgf/mm 2................. Kilogramme per square centimetre kgf/cm2................. Kilogramme metres (torque) kgf.m.............................. Kilometres km.............................................................. Kilometres per hour km/h............................................. Kilovolts kV................................................................... Left-hand LH................................................................ Left-hand steering LHStg............................................. Left-hand thread LHThd............................................... Litres litre.....................................................................Low tension l.t.............................................................. Maximum max............................................................. Metre m........................................................................ Millilitre ml.................................................................... Millimetre mm............................................................... Miles per gallon mpg.................................................... Miles per hour mph...................................................... Minute (angle) ............................................................ Minus (of tolerance) -................................................... Negative (electrical) -................................................... Newton metres (torque) Nm........................................ Number No.................................................................. Ohms ohm................................................................... Ounces (force) ozf....................................................... Ounces (mass) oz........................................................ Ounce inch (torque) ozf.in........................................... Outside diameter O.D.................................................. Part number Part No.................................................... Percentage %............................................................... Pints pt......................................................................... Pints (US) US pt........................................................... Plus (tolerance) +......................................................... Positive (electrical) +.................................................... Pound (force) lbf.......................................................... Pounds inch (torque) in.lbf........................................... Pound (mass) lb........................................................... Pounds per square inch P.S.I...................................... Ratio :........................................................................... Reference ref............................................................... Revolution per minute rev/min..................................... Right-hand RH............................................................. Second (angle) ........................................................... Second (numerical order) 2nd...................................... Specific gravity sp.gr.................................................... Square centimetres cm 2............................................... Square inches in2......................................................... Standard wire gauge s.w.g.......................................... Synchroniser/Synchromesh synchro........................... Third 3rd....................................................................... Top dead centre TDC.................................................. United Kingdom UK...................................................... Vehicle Identification Number VIN............................... Volts V......................................................................... Watts W....................................................................... SCREW THREADS American Standard Taper Pipe NPTF......................... British Standard Pipe BSP........................................... Unified Coarse UNC.................................................... Unified Fine UNF.........................................................
INTRODUCTION 11 INFORMATION CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY NEW TERM (ACRONYM) Accelerator pedal (AP)................................................. Air cleaner (ACL).......................................................... Air conditioning (AC).................................................... Battery positive voltage (B+)........................................ Closed loop (CL).......................................................... Closed throttle position (CTP)...................................... Canister purge valve (CANPV).................................... Data link connector (DLC)........................................... Diagnostic trouble code (DTC)..................................... Distributor ignition (DI)................................................. Engine control module (ECM)...................................... Engine coolant level (ECL)........................................... Engine coolant temperature (ECT).............................. Engine coolant temperature sensor (ECTS)................ Engine speed (RPM).................................................... Evaporative emission system (EVAP).......................... Engine fuel temperature sensor (EFTS)...................... 4th gear, 3rd gear etc. (4GR, 3GR).............................. Fuel pump (FP)............................................................ Fan control module (FCM)........................................... Generator (GEN).......................................................... Ground (GND).............................................................. Heated oxygen sensor (H02S).................................... Idle air control (IAC)...................................................... Idle air control valve (IACV)......................................... Ignition control module (ICM)....................................... Inertia fuel shutoff (IFS)................................................ Inertia fuel shutoff switch (IFSS).................................. Intake air temperature (IAT)......................................... Malfunction indicator lamp (MIL).................................. Manifold vacuum zone (MVZ)...................................... Mass air flow sensor (MAFS)....................................... Multiport fuel injection (MFI)........................................ On board diagnostic (OBD).......................................... Open loop (OL)............................................................ Park/neutral position (PNP)......................................... Park/neutral position switch (PNPS)............................ Programmable read only memory (PROM).................. Relay module (RM)...................................................... Service reminder indicator (SRI).................................. Solid state relay module (SSRM)................................. Three way catalytic converter (TWC).......................... Throttle body (TB)........................................................ Throttle position sensor (TPS)...................................... Torque converter clutch (TCC).................................... Transmission range (TR).............................................. Transmission range selector (TRS)............................. Vehicle speed sensor (VSS)........................................ Wide open throttle (WOT)............................................OLD TERM (ACRONYM) Throttle pedal (-).......................................................... Air cleaner (-)............................................................... Air conditioning (AC).................................................... Battery plus, bat +, bat feed (B+)................................. Closed loop (-)............................................................. Closed throttle, idle position (-).................................... Charcoal canister purge valve (-)................................. Serial link (-)................................................................ Fault code (-)............................................................... Electronic ignition (-).................................................... Electronic control unit (ECU)........................................ Coolant level (-)........................................................... Coolant temperature (temp)......................................... Coolant temperature thermistor (-).............................. Engine speed (rev/min)................................................ Evaporative loss system (ELC)................................... Fuel temperature thermistor (-).................................... Fourth gear, 3rd gear (-).............................................. Fuel pump (-)............................................................... Condenser fan timer (-)................................................ Alternator (-)................................................................ Ground, earth (B-)........................................................ Lambda (02) sensor (-)................................................ Idle speed control (ISC)................................................ Stepper motor (-)......................................................... Ignition module (-)........................................................ Inertia switch (-)........................................................... Inertia switch (-)........................................................... Intake temperature/ambient temperature (-)................ EFI warning lamp (-).................................................... Manifold depression, vacuum (-)................................. Air flow meter (-).......................................................... Electronic fuel injection (EFI)....................................... Fault code display unit (-)............................................ Open loop (-)............................................................... Park or neutral (-)......................................................... Start inhibit switch (-)................................................... Chip, PROM (PROM)................................................... Relay (-)....................................................................... Check engine light (-)................................................... Control unit (-).............................................................. Catalyst, catalytic converter (CAT).............................. Throttle housing (-)...................................................... Throttle potentiometer (-)............................................. Direct drive clutch (DDC).............................................. Transmission gear (-)................................................... Shift lever, shifter (-).................................................... Road speed transducer (-)........................................... Full throttle, wide open throttle (WOT).........................
01INTRODUCTION 12 INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate located under the bonnet [hood] riveted to the front of the engine compartment. Vehicle Identification Number Plate (UK, Australia, R.O.W., Europe) A.Build date (Australia). Type approval B.VIN (17 digits) C.Maximum permitted laden weight for vehicle D.Maximum vehicle and trailer weight E.Maximum road weight-front axle F.Maximum road weight-rear axle The number is also stamped on the right side of the chassis forward of the spring mounting turret. Vehicle Identification Number Plate (Saudi Arabia) A.Year of manufacture B.Month of manufacture C.Maximum vehicle weight D.Maximum road weight-front axle E.Maximum road weight-rear axle F.VIN (17 digits) The vehicle identification number identifies the manufacturer, model range, wheel base, body type, engine, steering, transmission, model year and place of manufacture. The following example shows the coding process. SALWorld manufacturer identifier LHRange Rover or LJDiscovery GClass 100 inch B2 door F300 Tdi or VV8i Petrol 85 speed LHD or 75 speed RHD M1995 MY ASolihull site
INTRODUCTION 13 INFORMATION European vehicle identification number (VIN) Stamped on the right hand side chassis forward of rear wheel. Federal (USA) vehicle identification number Stamped on a plate rivetted to the upper left hand A - post, visible through the front screen of the vehicle.Vehicle identification number (VIN) An adhesive label containing the Vehicle Identification Number, date of manufacture and gross axle weight ratings is fixed to the lock face of the front left hand door. The information includes wheel and tyre sizes and tyre pressures at gross axle weight ratings. Key to vehicle identification label A.Month and year of manufacture B.Gross vehicle weight rating C.Gross axle weight rating for front axle D.Gross axle weight rating for rear axle E.Vehicle identification number (17 digits) F.Vehicle identification number - bar code
01INTRODUCTION 14 INFORMATION LOCATION OF IDENTIFICATION NUMBERS Engine serial number - V8i engine Stamped on a cast pad on the cylinder block, between numbers 3 and 5 cylinders. Engines are identified by the prefix: 3.9 Litre: 35D. - 9.35:1 compression, manual transmission 36D. - 9.35:1 compression, automatic transmission 37D. - 8.13:1 compression, manual transmission 38D. - 8.13:1 compression, automatic transmission 4.2 Litre: 40D. - 8.94:1 compression, automatic transmission Engine serial number - Diesel engine Stamped on the RH side of cylinder block above the camshaft front cover plate.Main gearbox R380 Stamped on a cast pad on the bottom right hand side of the gearbox. Automatic gearbox Stamped on a plate riveted to the bottom left hand side of the gearbox casing.
INTRODUCTION 15 INFORMATION Transfer gearbox-Borg Warner Stamped on a plate attached to the gearbox casing, between filler/level and drain plug. Front and rear axle Stamped on the top of the left hand axle tubes.
01INTRODUCTION 16 INFORMATION FAULT DIAGNOSTIC EQUIPMENT TESTBOOK Todays Land Rover Vehicles are equipped with a large amount of electronics to provide the best performance of the vehicles systems. Diagnostic equipment named TESTBOOK is available to expand the diagnostic abilities of the dealer workshop. This repair manual is produced with Testbook in mind. Features of Testbook include: - Fully upgradable support for the technician. Structured diagnostics to accommodate all skill levels. Touch screen operation. Direct print out of screen information and test results. ELECTRICAL TROUBLESHOOTING MANUAL The Electrical Troubleshooting Manual is a separate publication that is intended for use by trained Land Rover technicians as an aid to diagnosing electrical concerns. It provides circuit diagrams, system diagnosis flow charts, electrical component location tables, electrical component location views, and circuit operation details.READING THIS MANUAL This manual is divided into sections shown on the contents page, alongside a rang of icons, familiar to service technicians. Relevant information is contained within each of these sections. These are further divided into the following sub-sections which appear at the foot of each page: Description and operation. Fault diagnosis. Adjustment. Repair. Overhaul. Specifications, Torque. Service tools. To avoid repeating information through the sections, where part of the repair operation impacts on another section, a cross reference is given to direct the reader to where the information is sited. For example: The maintenance section states the need to renew V8i drive belt. A cross reference sites this information in: Section: V8i Engine - Sub-section: Repairs - Heading: Drive belt renew Sections that contain derivatives such as engines are further separated into within that section. American terminology A few words used in this manual differ to words used in America. Where this occurs the American word is placed inside brackets. For example: bonnet [hood], wing [fender], ramp [hoist].
GENERAL SPECIFICATION DATA 1 INFORMATION ENGINE - V8 Type 3.9 litre V8................................................................................. Number of cylinders Eight, two banks of four......................................................... Bore 94.00 mm................................................................................. Stroke 71.12 mm............................................................................... Capacity 3950 cm 3........................................................................... Valve operation Overhead by push-rod................................................................ Compression ratio 8.13:1 or 9.35:1............................................................ Valve operation Overhead by push-rod................................................................ Maximum power: - 8.13:1 127kW at 4550 rev/min............................ - 9.35:1 134kW at 4750 rev/min............................ Type 4.2 litre V8................................................................................. Number of cylinders Eight, two banks of four......................................................... Bore 94.00 mm................................................................................. Stroke 77.00 mm............................................................................... Capacity 4275 cm 3........................................................................... Valve operation Overhead by push-rod................................................................ Compression ratio 8.94:1............................................................ Valve operation Overhead by push-rod................................................................ Maximum power 149kW at 4850 rev/min............................................................... Crankshaft Main journal diameter 58.409-58.422 mm....................................................... Minimum regrind diameter 57.393-57.406 mm............................................... Crankpin journal diameter 50.800-50.812 mm................................................ Minimum regrind diameter 49.784-49.797 mm............................................... Crankshaft end thrust Taken on thrust washers of centre main bearing....................................................... Crankshaft end float 0.10-0.20 mm......................................................... Main bearings Number and type 5, Vandervell shells.............................................................. Material Lead-indium............................................................................ Diametrical clearance 0.010-0.048 mm....................................................... Undersize bearing shells 0.254 mm, 0.508 mm.................................................. Connecting rods Type Horizontally split big-end, plain small-end................................................................................. Length between centres 143.81-143.71 mm................................................... Big-end bearings Type and material Vandervell VP lead-indium............................................................ Diametrical clearance 0.015-0.055 mm....................................................... End-float crankpin 0.15-0.36mm............................................................ Undersize bearing shells 0.254 mm, 0.508 mm.................................................. Piston pins Length 72.67-72.79 mm.............................................................................. Diameter 22.215-22.220 mm.......................................................................... Fit-in connecting rod Press fit......................................................... Clearance in piston 0.002-0.007 mm..........................................................
04GENERAL SPECIFICATION DATA 2 INFORMATION Pistons Clearance in bore, measured at bottom of skirt at right angles to piston pin 0.018-0.041 mm................................... Piston rings Number of compression rings 2.......................................... Number of control rings 1.................................................... No 1 compression ring Molybdenum barrel faced..................................................... No 2 compression ring Tapered and marked T or TOP..................................................... Width of compression rings 1.478-1.49 mm.............................................. Compression ring gap 0.40-0.65 mm...................................................... Oil control ring type Hepworth and Grandage.......................................................... Oil control ring width 3.0 mm......................................................... Oil control ring rail gap 0.38-1.40 mm..................................................... Camshaft Location Central........................................................................... Bearings Tin-aluminium........................................................................... Number of bearings 5.......................................................... Drive Chain 9.52 mm pitch x 54 pitches.................................................................................. TappetsHydraulic self-adjusting ........................................................................... Valves Length: Inlet 116.59-117.35 mm.................................. Exhaust 116.59-117.35 mm........................... Seat angle: Inlet 45°- 45 1/2° .................................. Exhaust 45°- 45 1/2° ........................... Head diameter: Inlet 39.75-40.00 mm.................................. Exhaust 34.226-34.480 mm........................... Stem diameter: Inlet 8.664-8.679 mm.................................. Exhaust 8.651-8.666 mm........................... Stem to guide clearance: Inlet 0.025-0.066 mm.................................. Exhaust 0.038-0.078 mm........................... Valve lift (Inlet and Exhaust) 9.49 mm............................................ Valve spring length fitted 40.4 mm at pressure of 29.5 kg.................................................. Lubrication System type Wet sump, pressure fed..................................................................... Oil pump type Eccentric rotor................................................................... Oil pressure 2.75 bar (40 lbf/in 2) at 2500 rev/min with engine at ...................................................................... running temperature Oil filter-internal Wire screen, pump intake filter in sump................................................................ Oil filter-external Full flow, self-contained cartridge...............................................................