Land Rover Warranty Codes Rover Manual
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LAND ROVER WARRANTY CODES MANUAL WARRANTY CODES MANUAL CONTENTS Introduction ................................ .................................................................................1 Complaint Code Index ................................................................................................ 2 Section 1 - Engine ................................ .......................................................................4 Section 2 - Engine, Auxiliaries ....................................................................................6 Section 3 - Power Train, Clutch, Manual Gearbox ......................................................8 Section 4 - Automatic Gearbox, Final Drive ................................................................ 10 Section 5 - Chassis, Steering & Suspension ..............................................................12 Section 6 - Brakes ................................ .......................................................................14 Section 7 - Electrical & Instruments ............................................................................16 Section 8 - Body Interior & Locks ................................................................................18 Section 9 - Body Exterior ............................................................................................20 Paint Refinishing Codes - Introduction .......................................................................22 Paint Refinishing Codes - Complaint Codes ................................ ...............................23 Publication Part No. LRL 0096ENG (c) 1997 Rover Group Limited
1 INTRODUCTION USING THESE CODES These codes are used to analyse warranty claims and consist of four digits in the sequence,number - letter - number. SELECTING THE CORRECT CODE To establish a code, select the appropriate section from the index e.g: Section 1 Engine, or Section 6 Brakes, or Section 9 Body ExteriorThe section number becomes the first digit of the complaint codeTurn to section page and select the complaint area e.g:1E Piston and Connecting Rod, or 6H ServoSystemThe component area reference letter becomes the second digit of the complaint code Then identify the individual part or assembly e.g: 1E3 Gudgeon pin, or 6H4 Non-Return ValvesThe part or assembly reference number becomes the third digit of the complaint code To complete the complaint code with the fourth digit, select from the bottom of the sectionpage that description which accurately fits the cause of the component or assembly failuree.g: 1E3F Gudgeon Pin Seized, or 6H4D Non-return Valve broken The fault description reference letter completes the complaint code.It is essential that your interpretation of the cause of the failure is accurate and that you avoid coding the result eg. clutch slipping - oil on drive plate; select a complaint codewhich describes what has caused the oil leak, not a code which describes the clutch driveplate contaminated with oil. PAINT CODESWhilst the layout of the page is different the procedure for selecting a code remains broadly the same. An example is given on the title page of the paint code section. IF YOU HAVE DIFFICULTY Contact the Warranty Department at Service Division, P.O. Box 58, Cowley, Oxford, OX4 2HU, England.
2COMPLAINT CODE INDEX SECTION 1 - ENGINE 1A BLOCK 1B SPECIAL CONDITIONS 1C CRANKSHAFT 1E PISTON AND CON© ROD 1F CYLINDER HEAD 1G VALVE GEAR 1H VALVE GEAR 1J VALVE GEAR 1K CAMSHAFT DRIVE 1M CAMSHAFT DRIVE 1N COVERS AND PLATES 1Q SEALS AND RINGS 1R CRANKCASE BREATHING 1S JOINTS AND GASKETS 1T CRANKCASE BREATHING 1U EXHAUST GAS RECIRCULATION SECTION 2 - ENGINE AUXILIARIES 2A LUBRICATION 2C COOLING 2D COOLING 2E WATER HOSES 2F AIR CLEANER INTAKE 2G BELT DRIVES AND PULLEYS 2H BELT DRIVERS AND PULLEYS 2J CARBURETTOR/MANIFOLD 2K CARBURETTOR 2L CARBURETTOR 2M DIESEL - ELECTRONIC FUEL INJECTION 2N FUEL SYSTEM 2P DIESEL INJECTION 2Q FUEL SYSTEM 2R FUEL SYSTEM 2S EXHAUST SYSTEM 2T EXHAUST SYSTEM 2U SEALS AND JOINTS 2V SEALS AND JOINTS 2W CRUISE SPEED CONTROL 2X CRUISE SPEED CONTROL 2Y TURBOCHARGER AND AUXILIARIES 2Z EXHAUST SYSTEM SECTION 3 - PT, CLUTCH, MANUAL GEARBOX ANDOVERDRIVE 3A CLUTCH AND RELEASE MECHANISM 3B CLUTCH AND RELEASE MECHANISM 3C GEARS 3D GEARBOX CASE/COVERS 3E GEARS 3F GEARBOX EXTERNAL 3G SYNCHROMESH AND HUBS 3H SHAFTS AND BEARINGS 3J GEARCHANGE EXTERNAL 3K SPECIAL CONDITIONS 3L TRANSFER CASING/GEARS 3M GEARCHANGE INTERNAL 3N TRANSFER SHAFTS/BEARINGS 3P SYNCROMESH HUBS 3Q SHAFT AND GEARS 3R SEALS AND JOINTS 3S SEALS AND JOINTS 3T MISCELLANEOUS COMPONENTS 3U POWER TAKE OFF 3V POWER TAKE OFF UNITS 3W TRANSFER GEARBOX (VISCOUS) 3X TRANSFER GEARBOX (SPECIAL CONDITIONS) 3Y GEAR CHANGE AND INTERNAL 3Z SEALS AND JOINTS SECTION 4 - AUTOMATIC GEARBOX AND FINAL DRIVE 4A FINAL DRIVE 4B AUTOMATIC GEARBOX EXTERNAL 4C AUTOMATIC GEARBOX INTERNAL 4D AUTOMATIC GEARBOX INTERNAL 4E AUTOMATIC GEARBOX INTERNAL 4F AUTOMATIC GEARBOX CONTROLS 4G AUTO BOX SPECIAL CONDITIONS 4H SEAL JOINTS 4J AUTO BOX SEALS/JOINTS 4K P©SHAFT G©BOX TO AXLE 4L DRIVE SHAFT TO WHEEL 4M AUTO BOX REPLACEMENT 4N FINAL DRIVE/AXLE CASE 4P FRONT AXLE GEARS AND PINIONS 4Q AXLE GEARS AND PINIONS 4R REAR AXLE GEARS AND PINIONS 4S DIFFERENTIAL SEALS AND JOINTS SECTION 5 - CHASSIS STEERING AND SUSPENSION 5A CHASSIS AND FITTINGS 5B CHASSIS AND FITTINGS 5C RUBBER MOUNTINGS 5D STEERING COLUMN 5E STEERING LINKAGE 5F STEERING BOX 5G POWER STEERING PUMP/HOSES 5H FRONT SUSPENSION 5J FRONT SUSPENSION 5L REAR SUSPENSION 5M REAR SUSPENSION 5N FRONT SPRINGS 5P REAR SPRINGS 5R SHOCK ABSORBERS 5T LEVELLING UNIT 5V FRONT HUBS 5W REAR HUBS 5X WHEELS AND TYRES 5Y AIR SUSPENSION 5Z AIR SUSPENSION SECTION 6 - BRAKES 6A TRANSMISSION BRAKE 6B TRANSMISSION BRAKE 6C DISC BR AKE FRONT 6D DISC BRAKE REAR 6F DRUM BRAKES REAR 6G MASTER CYLINDER/PIPES 6H SERVO SYSTEM 6J BRAKE PEDAL ASSEMBLY 6K BRAKES ANTI LOCK 6L BRAKES ANTI LOCK 6M TRACTION CONTROL
3 SECTION 6 - 6N ONWARDS - ELECTRICAL AND INSTRUMENTS 6N LIGHTS 6P SWITCHES 6Q WASHERS 6R AIR SUSPENSION 6S ALARM SYSTEM 6T AIR BAG 6U CONTROL UNITS 6V ELECTRIC WINDOWS AND SUNROOF 6W AIR SUSPENSION 6X RADIO/TAPE SYSTEM 6Y HEATER AND AIR CONDITIONING 6Z RADIO/TAPE SYSTEM AND MISCELLANEOUS SECTION 7 - ELECTRICAL AND INSTRUMENTS 7A IGNITION SYSTEM 7B IGNITION SYSTEM 7C STARTING SYSTEM 7D CHARGING AND ENGINE MISC 7E CHARGING SYSTEM AND ENGINE MISC 7F ENGINE MISCELLANEOUS 7G ELECTRONIC FUEL INJECTION 7H TRANSMISSION 7J LIGHTS 7K LIGHTS 7L LIGHT SWITCHES 7M SWITCHES, RELAYS ETC 7N BRAKES 7P SEAT BELT WARNING 7Q WASHERS AND HORNS 7R WIPERS 7S HEATING AND AIR CONDITIONING 7T INSTRUMENTS 7U INSTRUMENTS 7V INSTRUMENTS 7W ELEC INJECTION AND EMISSION 7X ELECTRIC WINDOW 7Y WIRING HARNESS 7Z MISCELLANEOUS SECTION 8 - BODY AND INTERIOR AND LOCKS 8A SEATS 8B SEATS 8C TRIM AND INSULATION 8D TRIM AND INSULATION 8E TRIM AND INSULATION 8F WINDOW CATCHES/MECHANISM 8G WINDOW GLASS 8H SEATS 8J HEATED SEATS 8K ELECTRIC DOOR LOCK 8L TRIM AND INSULATION 8M HEATING 8N HEATING/AIR-CONDITIONING 8P SEAT BELTS 8Q AIR CONDITIONING 8R AIR CONDITIONING (ELECTRIC) 8S INTERIOR FITTINGS 8T TOOLS/INTERIOR FITTINGS 8U SIDE DOOR LOCKS, ETC 8V TAIL DOOR LOCKS, ETC 8W MISCELLANEOUS LOCKS 8X AIR BA G 8Y SEAT BELTS 8Z MISCELLANEOUS SECTION 9 - BODY EXTERIOR 9A SHELL AND FIXED PANELS 9B SHELL AND FIXED PANELS 9C MOVING HINGED PANELS 9D FRONT SUNROOF 9E SOFT/HARD TOP 9F HINGES AND SUPPORTS 9G HINGES AND SUPPORTS 9H SEALS 9J SEALS 9K BODY AND FIXED PANEL WELDS 9L BODY SEAMS 9M EXTERIOR FITTINGS 9N EXTERIOR FITTINGS 9P EXTERIOR COVERINGS 9Q EXTERIOR COVERINGS 9R EXTERIOR FITTINGS 9S REAR SUNROOF 9T COACH LINE/TAPE 9U BODY SEAM FILLER EXTERNAL 9V BODY SEAM FILLER EXTERNAL 9W TACHOGRAPH 9Y SEALS 9Z BODY MISCELLANEOUS
4 SECTION 1 - ENGINE 1A BLOCK 1BSPECIAL CONDITIONS 1CCRANKSHAFT 1 BLOCK 1EXCESSIVE OIL CONSUMPTION 1CRANKSHAFT 2 BORES 2ENGINE OVERHEATING 2SPIGOT BUSH/BEARING 3 OILWAYS/DRILLINGS 3ENGINE RUNNING ON 3MAIN BEARING 4 LINERS 4EXCESSIVE SMOKE 4BIG END BEARING 5 CORE PLUGS 5ENGINE VIBRATION 5THRUST WASHERS/BEARINGS 6 DIPSTICK AND TUBE 6PINKING 6FLYWHEEL 7 CROSS BOLTS 7SHUNTING/SURGING 7STARTER RING GEAR 8 TAPPINGS STUDS AND SCREWS 8 8OIL WAYS/DRILLINGS 9 MAIN BEARING CAPS AND BOLTS 9ENGINE OIL LEVEL LOW 9VIBRATION DAMPER 0 0ENGINE OIL LEVEL HIGH 0CRANKSHAFT GEAR/PULLEY BOLT MOUNTINGS SEE 5C USE ONLY FOURTH DIGIT ©X©CONVERTER DRIVE PLATE 4A5 1DBEARING LADDER 1EPISTON AND CONNECTING ROD 1FCYLINDER HEAD 1 LADDER FRAME 1PISTON 1CYLINDER HEAD 2 OIL FEED RAIL 2PISTON RINGS 2VALVE SEATS 3 INTERNAL OIL GALLERIES 3GUDGEON PIN 3VALVE GUIDES 4 4LITTLE END BEARING 4CYLINDER HEAD CORE PLUGS 5 5CONECTING ROD AND CAP 5CAMSHAFT CARRIER/BRG. CAPS 6 6CONNECTING ROD CAP BOLTS/NUTS 6INJECTOR SLEEVE 7 7GUDGEON PIN CIRCLIP 7COMBUSTION CHAMBER HOT PLUG 8 TAPPINGS, STUDS & SCREWS 8 8TAPPINGS/STUDS/SCREWS/BOLTS 9 99 0 00 *CYLINDER HEAD BOLTSHEAD GASKET 1S6 1G VALVE GEAR 1HVALVE GEAR 1JVALVE GEAR 1 INLET VALVE 1CAMSHAFT ROLLER 1BRASS TAPPET SLIDE 2 INLET VALVE SPRING 2HYDRAULIC TAPPET 2TAPPET GUIDE 3 INLET VALVE SPLIT COTTERS 3ROCKER SHAFT PEDESTALS 3TAPPET GUIDE-BOLT 4 EXHAUST VALVE 4PUSH ROD 4 5 EXHAUST VALVE SPRING 5ROCKER AND SCREW/LOCKNUT 5 6 EXHAUST VALVE SPLIT COTTERS 6ROCKER SHAFT 6 7 CAP-SPRING 7SHIMS 7 8 CAP-VALVE STEM 8CAMSHAFT 8 9 VALVE STEM SEAL-INLET 9CAMSHAFT BEARINGS 9 0 VALVE STEM SEAL-EXHAUST 0CAMSHAFT RETAINER PLATE 0 1KCAMSHAFT/DRIVE 1LTWIN CAMSHAFTS 1MCAMSHAFT/DRIVE GEAR 1 CRANKSHAFT SPROCKET/GEAR 1EXHAUST CAMSHAFT 1 2 INTERMEDIATE/IDLER SPROCKET 2INLET CAMSHAFT 2OIL PUMP DRIVE GEAR 3 CAMSHAFT SPROCKET/GEAR/DAMPER 3 3VERTICAL DRIVE GEAR 4 WOODRUFF KEY-CAMSHAFT 4 4FUEL PUMP D GEAR/PLUNGER 5 DRIVE CHAIN 5 5IDLER/IDLER GEAR 6 VACUUM PUMP-INTERNAL 6 6 7 77FUEL INJECTION PUMP GEAR 8 CHAIN GUIDES 8 8 9 TENSIONER 9 9V8 DISTRIBUTOR DRIVE GEAR 0 00 (CAMSHAFT DRIVE BELT SEE 2G8VACUUM PUMP-EXTERNAL SEE 6H2) A WRONGLY ADJUSTED ECRACKED/SPLIT/CUT JWORN/STRETCHED B POROUS/ADRIFT FSEIZED/STIFF KNOISY/CHAFED C BAD FIT GLOOSE L D BROKEN HCORRODED/PLATING FAILURE MCOOLANT LEAKS
5 SECTION 1 - ENGINE 1N COVERS AND PLATES 1P 1QSEALS AND RINGS 1 SUMP 1 1FRONT CRANK/TIMING COVER SEAL 2 OIL FILLER CAP 2 2CRANKSHAFT REAR SEAL 3 33VALVE STEM SEAL 4 ROCKER COVER/CAMSHAFT COVER 4 4MAIN BEARING CAP SEAL 5 SIDE COVER 5 5FLYWHEEL HOUSING SEAL 6 FRONT/TIMING COVER 6 6CAMSHAFT OIL SEAL 7 REAR COVER/BACKPLATE 7 7 8 88 9 SUMP PLUG 9 9DISTRIBUTOR OIL SEAL 0 WADING PLUG 0 0LINER SEALS JOINTS/GASKETS SEE 1S 1R CRANKCASE BREATHING 1SJOINTS/GASKETS 1TCRANKCASE BREATHING 1 PCV FILTER ELEMENT 1TOP ROCKER CAMSHAFT COVER 1OIL SEPARATOR 2 PCV VENT CRANKCASE 2FRONT TIMING COVER 2TOP BREATHER HOSE 3 PCV RESTRICTOR T PIECE 3SIDE COVER 3 4 4REAR COVER/BACKPLATE 4BOTTOM BREATHER HOSE 5 5SUMP/TRANSMISSION CASE 5TOP BREATHER VALVE 6 6HEAD GASKET 6BOTTOM BREATHER VALVE 7 7CAMSHAFT END COVER 7HOSES/CLIPS 8 8INJECTOR HEAT SHIELD WASHERS 8CRANK/CLUTCH BREATHER 9 9CAM CARRIER TO CYLINDER HEAD 9REGULATOR VALVE 0 0BRG. LADDER TO CYLINDER HEAD 0ONE WAY VALVE * MAIN BEARING CAP SEAL 1Q4 MANIFOLD JOINTS SEE 2U 1U EXHAUST GAS RECIRCULATION 1V 1W 1 E G R VALVE 1 1 2 E G R GAS PIPES 2 2 3 E G R VACUUM CONTROL PIPES 3 3 4 E G R CUT OFF VALVE 4 4 5 E G R FUEL TRAP 5 5 6 E G R COOLER 6 6 7 77 8 88 9 99 0 00 1X1Y1Z 1 11 2 22 3 33 4 44 5 55 6 66 7 77 8 88 9 99 0 00 NLEAKS NOT COOLANT LOSS SOPEN CIRCUIT/BLOCKED WVIBRATION/OUT OF BALANCE P TTHREAD DAMAGE XSPECIAL CODES ONLY Q UY R FACTORY DAMAGE VINACCURATE/SLIPPING ZINOPERATIVE
6 SECTION 2 - ENGINE AUXILARIES 2A LUBRICATION 2BLUBRICATION 2CCOOLING 1 OIL PUMP 1 1FAN 2 SUMP PICKUP/STRAINER 2 2VISCOUS DRIVE 3 RELIEF VALVE/SEAT 3 3WATER PUMP 4 SQUIRT JET 4 4THERMOSTAT 5 EXTERNAL/TURBO OIL PIPES 5 5RADIATOR 6 OIL FILTER/ADAPTOR 6 6HEADER TANK 7 OIL COOLER ENGINE 7 7EXPANSION/OVERFLOW TANK 8 OIL PUMP DRIVE SHAFT 8 8DRAIN TAPS 9 OIL COOLER PIPES ENGINE 9 9EXPANSION TANK CAP 0 OIL FILTER HEAD/BOWL 0 0RADIATOR BLEED PLUG SUMP 1N1 ELECTRICAL FAN SEE 7F DIPSTICK 1A6 BELTS & PULLEYS SEE 2G 2H SWITCHES ETC SEE 7U 7V SWITCHES ETC SEE 7U 2DCOOLING 2EWATER HOSES 2FAIR CLEANER INTAKE 1 RADIATOR FILLER CAP 1TOP HOSE 1AIR CLEANER CASE 2 COWLING SURROUND 2BOTTOM HOSE 2INTAKE HOSE/INTAKE GRILL 3 COWLING/BRACKETS 3BY PASS HOSE 3BRACKETS AND CLIPS 4 RADIATOR MOUNTINGS 4HEATER SUPPLY HOSES 4AIR CLEANER ELEMENT 5 THERMOSTAT HOUSING 5HEATER RETURN HOSES 5AIR CLEANER DUMP VALVE 6 CYL HD BRIDGE RAIL VM DIESEL 6EXPANSION TANK HOSE 6AIR INTAKE SENSOR 7 Y PIECE/EJECTOR PUMP 7HEADER TANK TO RAD HOSE 7AIR INTAKE RESONATOR 8 COOLANT LEVEL SENSOR 8WATER HOSE CLIPS 8CROSSOVER DUCT DIESEL 9 9Y PIECE HOSES 9AIR CLEANER INDICATOR 0 ANTI-FREEZE MIX 0IRD THERMOSTAT/HSG 0TEMPERATURE CONTROL SENSOR ALSO SEE 2Z 2GBELT DRIVES AND PULLEYS 2HBELT DRIVES AND PULLEYS 2JCARBURETTER/INJECTION /MANIFOLD 1 CRANKSHAFT PULLEY/DAMPER 1VACUUM PUMP DRIVE PULLEY 1INLET MANIFOLD 2 ALTERNATOR PULLEY 2VACUUM PUMP DRIVE BELT 2INLET MANIFOLD FIXINGS 3 ALTERNATOR DRIVE BELT 3POWER STEERING JOCKEY PULLEY 3DIAPHRAGM 4 SERPENTINE DRIVE BELT 4POWER STEERING PUMP PULLEY 4CARBURETTER BODY 5 WATER PUMP DRIVE BELT 5POWER STEERING DRIVE BELT 5FLOAT CHAMBER AND PIPE 6 AIR CONDITIONING PUMP PULLEY 6 6FLOAT NEEDLE SEAT AND LEVER 7 AIR CONDITIONING PUMP BELT 7IDLER PULLEY 7FLOAT 8 CAMSHAFT DRIVE BELT 8WATER PUMP PULLEY 8BUTTERFLY AND SPINDLE 9 CAMSHAFT DRIVE BELT TENSIONER 9AUTO TENSIONER 9DASHPOT, PISTON AND DAMPER 0 AIR CONDITIONING JOCKEY PULLEY 0 0ACCELERATOR PUMP 2KCARBURETTER/INJECTION 2LCARBURETTER 2MDIESEL - ELECTRONIC FUEL INJECTION 1 JET ASSEMBLY 1TEMP COMPANSATING DEVICE 1ELECTRONIC DIESEL CONTROL 2 CHOKE 2 2ELECTRONIC EXHAUST GAS RE-CIRCULATION 3 CHOKE CONTROL 3TAPPINGS 3BOOST PRESSURE SENSOR 4 THROTTLE BODY 4 4GLOW PLUG RELAY 5 ACCELERATOR LINKAGE 5 5NEEDLE SENSOR INJECTOR 6 ACCELERATOR RETURN SPRING 6 6 7 ACCELERATOR PEDAL 7 7 8 88 9 CARBURETTER NEEDLE 9CARB VENT SOLENOID 9 0 HAND THROTTLE CONTROL AIRCLEANER SEE 2F 0 FUEL STOP VALVE & SOLENOID 0 AWRONGLY ADJUSTED ECRACKED/SPLIT/CUT JWORN/STRETCHED B POROUS/ADRIFT FSEIZED/STIFF KNOISY/CHAFED C BAD FIT GLOOSE LJUDDER/POOR CONNECTION D BROKEN HCORRODED/PLATING FAILURE M
7 SECTION 2 - ENGINE AUXILARIES 2N FUEL SYSTEM 2PDIESEL INJECTION 2QFUEL SYSTEM 1 ANTI SURGE VALVE 1INJECTION PUMP 1FUEL DELIVERY PUMP (MECHANICAL) 2 FLOAT/ROLLOVER VALVE 2INJECTORS 2FILTER (FUEL PUMP) 3 PRESSURE RELIEF VALVE 3INJECTOR PIPES 3AGGLOMERATOR/WATER TRAP 4 PURGE CONTROL VALVE 4FUEL RETURN SYSTEM 4RIGID PIPES AND UNIONS 5 FUEL RAIL 5STOP CONT/SHUT OFF VALVE 5FLEXIBLE PIPES AND UNIONS 6 FUEL TANK PRESSURE SENSOR 6ACCELERATOR LINKAGE CABLE 6CHANGE OVER TAP 7 FUEL TANK CRADLE 7ACCELERATOR RETURN SPRING 7NON RETURN VALVE 8 FUEL TANK HEATSHIELD 8VACUUM GOVERNOR/CONTROL UNIT 8FUEL TANK (MAIN) 9 CANNISTOR VENT SOLENOID 9STOP CONTROL CABLE/FUEL CUT OFF SOLENOID 9 FUEL TANK (AUXILLARY) 0 FUEL COOLER 0FAST IDLE UNITACCEL MECH SEE 2K 0 FUEL FILLER NECK* ELECTRIC PUMP 7F9FUEL CAP 9M3, FUEL CAP LOCK 8W6FUEL FILLER COVER 9P9 2RFUEL SYSTEM 2SEXHAUST SYSTEM 2TEXHAUST SYSTEM 1 CHARCOAL CANISTERS 1MANIFOLD 1RUBBER MOUNTINGS CENTRE/FRONT 2 BREATHER TUBES 2DOWN PIPE (RH CATALYST) 2HEAT SHIELDS 3 FUEL LINE FILTER 3DOWN PIPE 3STRAPS AND BRACKETS 4 ANTI RUN ON VALVE 4DOWN PIPE (LH CATALYST) 4CLAMPS 5 PLENUM CHAMBER 5INTERMEDIATE PIPE 5OXYGEN SENSOR (RH) 6 PRESSURE REGULATOR VALVE 6MANIFOLD HEATSHIELDS 6OXYGEN SENSOR (LH)/SINGLESENSOR 7 VAPOUR SEPERATOR/BREATHER 7FRONT SILENCER 7RUBBER MOUNTING REAR 8 EXPANSION TANK 8INTERMEDIATE/MAIN SILENCER 8MANIFOLD FIXINGS 9 FUEL TANK LOCKING RING(PUMPUNIT) 9 REAR SILENCER 9MANIFOLD HEATSHIELD FIXINGS 0 FUEL TANK FILLER NECK LOCKINGRINGSOLENOID 7WO 0 EXHAUST CATALST/CONTAINER ONESILENCER ONLY FITTED 2S8 0 MANIFOLD HEAT SHEILD FURTHERHEAT SHIELDS SEE 7C4, 7D4, 2Z 2USEALS AND JOINTS 2VSEALS AND JOINTS 2WCRUISE SPEED CONTROL 1 INLET MANIFOLD 1OIL FILTER SEAT HOUSING 1SPIRAL CASSETTE 2 INJECTION PUMP JOINT WASHER 2 2ECU 3 EXHAUST MANIFOLD 3 3ACTUATOR 4 EXHAUST FLANGE 4OIL PIPES ©O© RINGS 4THROTTLE LEVER AND CABLE 5 EXHAUST PIPE 5TANK UNIT 5PUMP 6 CARBURETTER FLANGE 6JET SEALS AND ©O© RINGS 6RESET BUTTON 7 CARBURETTER MISCELLANEOUS 7WATER PUMP 7BRAKE PEDAL SWITCH 8 THERMOSTAT HOUSING 8FUEL PIPE WASHERS AND SEALS 8CLUTCH PEDAL SWITCH 9 OIL PUMP HOUSING 9OIL PIPE BANJO WASHERS 9WIRING HARNESS 0 INJECTOR SEALING WASHERS COMBINED INLET EXHAUSTMANIFOLD GASKET 2U1 0 FUEL FILTER SEAL AND HOUSING 0ENGINE SPEED TRIP MODULE ROADSPEED TRANSDUCER SEE 7T2 2XCRUISE SPEED CONTROL 2YTURBOCHARGER AND AUXILIARIES 2ZAIR CLEANER INTAKE 1 ROTARY COUPLER 1TURBOCHARGER ASSEMBLY 1AIR INTAKE SENSOR 2 CONVERTER MODULE 2INTERCOOLER 2AIR INTAKE RESONATOR 3 3INTERCOOLER HOSE 3CROSS OVER DUCT DIESEL 4 4DUMP VALVE INTERCOOLER 4 5 5WASTE GATE VALVE 5 6 6OIL PIPE 6 7 7HEAT SHIELD 7 8 8BOOST CONTROL PIPE 8 9 99 0 00 ALSO SEE 2F NLEAKS SBLOCKED WVIBRATION/OUT OF BALANCE P TTHREAD DAMAGE XSURFACE DAMAGE Q UINACCURATE/SLIPPING YINTERMITTENT OPERATION R FACTORY DAMAGE V ZINOPERATIVE
8 SECTION 3 - POWER TRAIN CLUTCH, MANUAL GEARBOX 3A CLUTCH AND RELEASE MECHANISM 3BCLUTCH AND RELEASE MECHANISM 3CGEARS/SYNCHROMESH HUBS 1 COVER ASSEMBLY 1RELAESE FORK AND PINS 1REVERSE IDLER GEAR/BRG/SPACER 2 DRIVE PLATE ASSEMBLY 2RETURN SPRING 2CONSTANT PINION 3 RELEASE BEARING 3RELEASE BEARING LINKAGE 3REVERSE LAYSHAFT GEAR 4 RELEASE BEARING SLEEVE 4MASTER CYLINDER 4REVERSE BUSH SHIM 5 RELEASE PUSH ROD AND BUSH 5SLAVE CYLINDER 5REVERSE SYNCROMESH UNIT 6 RELEASE LEVER 6PEDAL ASSEMBLY 6REVERSE BULK RING 7 RELEASE LEVER PIVOT PIN 7PEDAL BUSHES 7REVERSE BRAKE 8 RELEASE FORK AND PINS 8HYDRAULIC PIPES 8 9 RELEASE BRG AND GUIDE 9HYDRAULIC DAMPER 9 0 CROSS SHAFT AND BUSH 0RELEASE BEARING AND GUIDE 0 ALSO SEE 3E 3DGEARBOX CASE/COVERS 3EGEARS 3FGEARBOX EXTERNAL 1 GEARBOX/TRANSMISSION CASE 1 1OIL COOLER 2 FLYWHEEL HOUSING 21ST WITH BUSHES/BEARINGS 2OIL COOLER PIPES 3 CLUTCH HOUSING END COVER 32ND WITH BUSHES/BEARINGS 3HILL DESCENT COLLAR SWITCH 4 GEARBOX BREATHER PIPE 43RD WITH BUSHES/BEARINGS 4 5 GEARBOX BREATHER 54TH WITH BUSHES/BEARINGS 5 6 CORE PLUGS 65TH WITH BUSHES/BEARINGS 6 7 DIFFERENTIAL SIDE COVER 7REVERSE WITH BUSHES/BEARINGS 7 8 REAR EXTENSION HOUSING 8LAYGEAR 8 9 REMOTE CONTROL HOUSING 9SPEEDO DRIVE GEAR AND BUSHES 9 0 SEALS & JOINTS SEE 3R 3S MOUNTINGS 5C2 0 OIL PUMPSEE ALSO 3C 0 3G SYNCHROMESH HUBS 3HSHAFTS AND BEARINGS 3JGEARCHANGE EXTERNAL 1 1ST SPEED SYNCHROMESH UNIT 1INPUT SHAFT 1GEAR LEVER AND KNOB 2 2ND SPEED SYNCHROMESH UNIT 2MAIN SHAFT 2SPHERICAL SEAT AND RETAINER 3 3RD SPEED SYNCHROMESH UNIT 3LAYSHAFT 3REMOTE CONTROL LINKAGE 4 4TH SPEED SYNCHROMESH UNIT 4REVERSE SHAFT 4REVERSE CATCH/PLUNGER 5 5TH SPEED SYNCHROMESH UNIT 5INPUT SHAFT BEARINGS 5HIGH/LOW CONTROL LEVER AND KNOB 6 1ST SPEED BAULK RING 6MAIN SHAFT BEARINGS 64 W D CONTROL LEVER AND KNOB 7 2ND SPEED BAULK RING 7LAYSHAFT BEARINGS 7LOWER PIN 8 3RD SPEED BAULK RING 8MAIN SHAFT SPIGOT BEARING 8SELECTOR ROD YOKE/BUSH 9 4TH SPEED BAULK RING 9OUTPUT FLANGE AND SPLINES 9BIAS SPRING 0 5TH SPEED BAULK RING SEE ALSO 3C 0 OIL PUMP THRUST WASHERS CIRCLIPS ANDRETAINING SEE 3TSEE ALSO 3Y 0 GEAR LEVER ANTI RATTLE DEVICESELECTOR SHAFT SEAL 3R9 3KSPECIAL CONDITIONS 3LTRANSFER/IRD CASING/GEARS 3MGEARCHANGE INTERNAL 1 1ST GEAR AUTO DISENGAGEMENT 1TRANSFER/IRD CASING/COVERS 11ST/2ND SELECTOR FORK 2 2ND GEAR AUTO DISENGAGEMENT 24 W D FORK SHAFT AND LINKAGE 23RD/4TH SELECTOR FORK 3 3RD GEAR AUTO DISENGAGEMENT 3HIGH/LOW SELECTOR MECHANISM 35TH SELECTOR FORK 4 4TH GEAR AUTO DISENGAGEMENT 4SPRINGS, BALLS AND PLUNGERS 4REVERSE SELECTOR FORK 5 5TH GEAR AUTO DISENGAGEMENT 5TRANSFER GEARS/IRD GEARS 5SELECTOR SHAFTS/RAILS 6 REVERSE AUTO DISENGAGEMENT 6LOW GEARS AND DOGS 6DETENT SPRINGS/BALLS/PLUNGERS 7 HIGH RANGE AUTO DISENGAGEMENT 7HIGH GEARS AND DOGS 7REVERSE LEVER/PIVOT 8 LOW RANGE AUTO DISENGAGEMENT 84 W D DOGS/DIFF LOCK DOGS 8INTERLOCK DEVICE 9 GEARBOX OIL LEVEL LOW 9TRANSFER BOX DIFFERENTIAL 95th/REV SELECTOR FORK 0 USE WITH 4TH DIGIT ©X© ONLY 0 (CONTINUED AT 3W) 0 HIGH/LOW SELECTOR FORKS ALSO SEE 3Y AWRONGLY ADJUSTED ECRACKED/SPLIT/CUT JWORN/STRETCHED B POROUS/ADRIFT FSEIZED/STIFF KNOISY/CHAFED C BAD FIT GLOOSE/WEAK SYNCHROMESH LJUDDER D BROKEN HCORRODED/PLATING FAILURE M