VEH G 104-1 Land Rover 110 4X4 All Types – Medium Grade Repair

ELECTRICAL AND MECHANICAL VEHICLE G 104-1 ENGINEERING INSTRUCTIONS Issue 3, Sep 14 TRUCK, UTILITY, LTWT AND TRUCK, UTILITY, LTWT, WINCH, MC2 - LAND ROVER 110 4X4 MEDIUM GRADE REPAIR This instruction is authorised for use by command of the Chief of Army. It provides direction, mandatory controls and procedures for the operation, maintenance and support of equipment. Personnel are to carry out any action required by this instruction in accordance with EMEI General A 001. TABLE OF CONTENTS Page No Page No Introduction ............................................................................5 Rear Axle............................................................................. 74 Items Previously Known To Have Contained Asbestos....5 Rear Axle Assembly ....................................................... 74 Paint ..................................................................................7 Reclamation of Rear Axle Lower Link Mounts................ 76 General Safety Warnings ..................................................7 Radius Arm Reclamation ................................................ 78 Publications.......................................................................8 Front Axle ............................................................................ 81 Location of Identification Numbers..................................10 Front Axle Assembly....................................................... 81 Special Tools and Gauges ..............................................11 Front Axle Specifications ................................................ 85 List of Lubricants .............................................................13 Differential Carrier........................................................... 86 ENGINE ..........................................................................14 Differential Carrier Specifications ................................... 88 Engine .............................................................................14 Reclamation of Worn Panhard Rod Mounts ................... 89 Cylinder Head .................................................................21 Reclamation of Worn Radius Arm Mounts...................... 90 Camshaft Followers ........................................................28 Suspension.......................................................................... 92 Oil Pump .........................................................................33 Front Springs .................................................................. 92 Oil Cooler ........................................................................36 Rear Springs................................................................... 93 Expansion Plugs .............................................................38 Suspension Specifications.............................................. 95 Flywheel and Ring-gear ..................................................39 Steering ............................................................................... 96 Crankshaft Oil Seal - Front..............................................39 Steering Box ................................................................... 96 Crankshaft Oil Seal - Rear ..............................................40 Steering Column ............................................................. 97 Special Tools for Crankshaft Rear Oil Seal.....................45 Steering Specifications ................................................. 102 Engine Specifications......................................................46 Frame ................................................................................ 103 Engine Fault Finding .......................................................47 Towing Pintle ................................................................ 103 Clutch...................................................................................48 Body .................................................................................. 104 Clutch Assembly .............................................................48 Bonnet .......................................................................... 104 Rectification of Jamming Clutch......................................49 Mudguard – Front Left .................................................. 104 Clutch Specifications.......................................................51 Mudguard – Front Right................................................ 106 Transmission .......................................................................52 Doors ............................................................................ 109 Transmission Assembly ..................................................52 Windscreen Glass......................................................... 109 Power Take Off (PTO) ....................................................59 Roll Over Protection...................................................... 112 Transfer Case .................................................................61 Fitting of Camouflage Net Carrier ................................. 112 Oil Pump Front Cover and Transmission Input Seal.......61 Rivnut Replacement Procedure.................................... 113 Rectification of Oil Transfer Between Transfer Case Cab Heating/Cooling ......................................................... 115 and Transmission............................................................63 Heater Assembly .......................................................... 115 Transfer Case Repair Procedure to Rectify Winch ................................................................................ 117 Disengagement ...............................................................66 Winch Assembly ........................................................... 117 Transmission Specifications............................................72 Winch Specifications..................................................... 119 LIST OF FIGURES Page No Page No Figure 1 Special Tools ..........................................................12 Figure 6 Fuel Lines ............................................................... 15 Figure 2 Grille Panel .............................................................14 Figure 7 Accelerator Control and Stop Levers...................... 16 Figure 3 Vacuum Line and Heater Hose Connections..........14 Figure 8 Alternator and Starter Motor Cables....................... 16 Figure 4 Air Cleaner ..............................................................15 Figure 9 Slave Cylinder ........................................................ 17 Figure 5 Front Exhaust Pipe .................................................15 Figure 10 Engine Lifting........................................................ 17 1 VEHICLE G 104-1 ELECTRICAL AND MECHANICAL Issue 3, Sep 14 ENGINEERING INSTRUCTIONS Figure 11 Slave Cylinder....................................................... 19 Figure 63 Coupling Pin Punch.............................................. 69 Figure 12 Bonnet Catch ........................................................ 20 Figure 64 Input Gear Coupling Assembly............................. 69 Figure 13 Side Cover Breather Connection .......................... 22 Figure 65 Intermediate Gear Assembly Preload Figure 14 Fuel Lines ............................................................. 22 Adjustment and Shim Selection.................................. 70 Figure 15 Rocker Shaft - Removal........................................ 23 Figure 66 Rear Axle Removal .............................................. 74 Figure 16 Cylinder Head Bolts - Removal............................. 23 Figure 67 Bottom Link to Axle Bracket ................................. 75 Figure 17 Checking Cylinder Head Distortion....................... 24 Figure 68 Top Link and Ball Joint Removal.......................... 75 Figure 18 Exhaust Manifold Gasket Installation.................... 25 Figure 69 Rear Lower Link .................................................. 77 Figure 19 Exhaust Manifold - Tightening Sequence............. 25 Figure 70 Front Axle Breather Hose Removal...................... 81 Figure 20 Inlet Manifold Gasket Installation.......................... 25 Figure 71 Radius Arm Bush Mounting.................................. 81 Figure 21 Cylinder Head Bolts Tightening Sequence........... 26 Figure 72 Tie Rod Removal.................................................. 82 Figure 22 Rocker Shaft Assembly Tightening Sequence ..... 27 Figure 73 Radius Arm Removal ........................................... 82 Figure 23 Clamp Plate Location............................................ 27 Figure 74 Front Shock Absorber Mounting........................... 82 Figure 24 Fuel Filter Installation............................................ 27 Figure 75 Drag Link Removal............................................... 83 Figure 25 Alternator Adjusting Bolts ..................................... 29 Figure 76 Brake Calliper Removal........................................ 86 Figure 26 Camshaft Follower Wear Patterns........................ 30 Figure 77 Steering Linkage Removal ................................... 87 Figure 27 Camshaft Follower Outside Dimensions............... 30 Figure 78 Panhard Rod Mount ............................................ 89 Figure 28 Aligning the Gear Timing Marks ........................... 31 Figure 79 Radius Arm Mounts............................................. 91 Figure 29 Oil Pump - Exploded View ...................................

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