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
intercooler.
8.Disconnect the EGR pipe from the inlet manifold
hose.
9.Remove the three fixings at the exhaust pipe
flange.
10.Release the turbo charger oil pipes from the
cylinder block.
11.Remove the turbo boost pipes.
12.Remove seven bolts securing the exhaust
manifold, release the heater rail and remove the
manifold gasket, complete with turbo unit.
13.Remove four bolts and disconnect diaphragm
rod from manifold, and remove turbo charger if
necessary.
Refit
14.Reverse removal procedure. 1 to 12. Use a new
manifold and exhaust flange gaskets.
15.Reconnect battery negative lead. Start engine
and check for leaks. 
						

							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 45................................................................................
Exhaust frontpipe to manifold 10....................................................................
Exhaust downpipe to silencer box 30.............................................................
Manifold chamber gasket 10........................................................................... 
						

							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 rings (2) for diaphragm spring
8. Retraction links and bolts (3) for pressure plate
9. Release bearing
10. Release lever11. Release lever pivot post
12. Master cylinder
13. Slave cylinder
14. Master cylinder pedal pushrod
15. Primary shaft and taper bearing (in gearbox)
16. Gearbox front cover
17. Primary shaft flywheel bush
18. Pedal pivot and return spring
19. Hydraulic damper (Diesel only) 
						

							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 takes up a neutral position between the
flywheel 1 and the pressure plate 5 , thus breaking the
drive between the engine and the gearbox.
NOTE: Diesel engined vehicles have an
hydraulic damper 19 fitted into the system.
The damper contains a steel diaphragm
which absorbs slight hydraulic pulses caused by
cyclic variations of the diesel engine crankshaft at
low rpm. 
						

							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
linings contaminated with oil, which may cause it
to stick or continue to run in contact with the
flywheel or pressure plate.
A number of faults can develop in the operation of the
clutch for a variety of reasons and although most
faults are due to normal wear at high mileage,
problems can also occur if the unit has been renewed
by an unskilled operator.
Recognising and diagnosing a particular clutch fault is
therefore of paramount importance in ensuring, that
the problem is rectified at the first attempt.
Problems which develop in the clutch are as follows:-
A. Clutch spin/drag
B. Clutch slip
C. Clutch judder/fierceCLUTCH SPIN - DRAG
Symptoms
Clutch spin is that, with engine running and clutch
pedal depressed, the gears cannot be immediately
engaged without making a grinding noise. This
indicates the clutch is not making a clean break.
However, if the clutch pedal is held depressed for
several seconds the friction plate will eventually break
free from the engine and the gear will engage silently.
Clutch spin as it becomes more severe develops into
clutch drag, making the silent engagement of a gear
impossible, regardless of how long the pedal is held
depressed.
CLUTCH SLIP
Symptoms
Clutch slip is most evident climbing a hill or when the
vehicle is moving off from stationary with a heavy
load. As the clutch is released slip occurs between the
engine and the transmission, allowing the engine
speed to increase without a corresponding increase in
vehicle speed.
Clutch slip can develop to the stage where no power
is transmitted through the clutch as the pedal is
released.
CLUTCH JUDDER - FIERCE
Symptoms
Clutch judder or fierce engagement, like slip, is most
likely to occur when the vehicle is moving off from
stationary. As the clutch pedal is released the vehicle
will move rapidly or in a series of jerks, which can not
be controlled even by careful operation of the clutch
by the driver.
It should be noted that a vehicle may display all the
symptoms or any combination of the symptoms
described, depending on the driving conditions vehicle
load and operating temperatures. 
						

							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 chart.See Description and operation, Description
CLUTCH NOISE - MECHANICAL FAULTS
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox input/primary shaft bearings.
See MANUAL GEARBOX, Fault diagnosis,
Manual Gearbox
- Noise from gearbox in neutral, which
disappears when clutch is depressed
Noise from clutch or gearbox in neutral, which
changes tone or becomes worse when the clutch
is depressed.
Suspect worn release bearing.
Knocking/rattling from clutch or gearbox in
neutral, which is reduced or disappears when the
clutch is depressed.
Suspect worn/weak release lever retainer or
clutch unit.
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox fault.
See MANUAL GEARBOX, Fault diagnosis,
Manual Gearbox
- Noise from gearbox in neutral, which
disappears when clutch is depressed.HYDRAULIC FAULTS
Unable to dis-engage clutch, little or no pedal
resistance.
1.Check condition, specification and level of fluid.
2.Check pipes and cylinders for leaks.
3.Check that air vent in reservoir lid is clear.
Suspect faulty master cylinder if no fluid leaks
present.
See Repair, Master Cylinder
Spongy pedal operation
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect air in fluid.
See Repair, Bleed Hydraulic System
Clutch is difficult to dis-engage and/or does not
immediately re-engage when pedal is released.
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect pedal pivot, master cylinder or slave
cylinder seizure.
See Repair, Master Cylinder 
						

							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 flywheel for
reassembly.
3.Remove clutch cover securing bolts, working
evenly and diagonally.
4.Do not disturb three bolts in clutch cover.
5.Remove clutch assembly.
6.Withdraw clutch driven plate.
Refit
NOTE: To prevent clutch plate sticking,
lubricate splines using Rocol MV 3 or
Rocol MTS 1000 grease.
7.Renew/refit clutch driver plate and clutch
assembly using centralising tool, where
applicable, align assembly marks.
8.Secure clutch assembly cover fixings evenly,
working in a diagonal sequence. Tighten to
28
Nm.
9.Fit gearbox to engine. 
						

							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 from tubing is free of air.
Keeping free end of tube below surface of fluid.
5.Hold clutch pedal down, tighten bleed screw.
6.Top up fluid reservoir.MASTER CYLINDER
Service repair no - 33.20.01/03
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Evacuate hydraulic fluid from system.
2.Disconnect fluid pipe at master cylinder. Plug
master cylinder fluid port and seal end of
hydraulic pipe to prevent ingress of foreign
matter.
3.Lower fascia fuse box panel.
4.Remove master cylinder fixings.
5.Remove retaining washer and clevis pin from
push rod and clutch pedal.
6.Remove master cylinder. 
						

							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 sleeve. Fit replacement bearing with
domed face outwards from sleeve.
5.Remove spring clip and fixings.
6.Withdraw release lever assembly.
Refit
7.Smear pivot with grease and fit release lever and
retain with spring clip and bolt.
8.Smear release bearing sleeve inner diameter
with molybdenum disulphide base grease.
9.Reverse removal procedure. 1 to 4. 
						

							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 Hylomar
P232M waterproof jointing compound.
7.Locate backing plate and dust cover in position
on slave cylinder.
8.Fit slave cylinder, engaging push-rod through
centre of dust cover and with bleed screw
uppermost.
9.Reconnect fluid pipe.
10.Replenish and bleed clutch hydraulic system.
11.Check for fluid leaks with pedal depressed and
also with system at rest.