Land Rover Series 1 Head Tightening Nuts.
Land Rover Series 1 Engine Front Profile.
Land Rover Series 1 Engine side profile.
Land Rover Series 1 Gearbox and Transfer Box Layout.
Land Rover Series 1 Steering Relay.
Land Rover Series 1 Steering Relay.
Land Rover Series 1 Bearing Housing.
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Dampers. - Type : non adjustable telescopic hydraulic. Anchorage : pins, rubber bushed to chassis side-member, and to road spring bottom plate. Special seal obviates the need for topping up, renew damper when ineffective.
Petrol Tank. - Location : under driver's seat, between two extended cross-members. Retention : tank and undershield, by six bolts and nuts. Filler cap under driver's seat. Capacity : 10 imperial gallons.
Lubrication. - Two points only, clutch and brake pedal shafts fitted with Tecalemit nipples.
Clutch (Rover Type)
Type. - Dry single plate, in own housing enclosed by outer housing between engine and gearbox.
Adjustment. - Nominal free pedal traverse : in. as measured at pedal pad and obtained by altering effective length of rod connecting operating lever to pedal shaft lever ; to increase pedal travel turn self-locking nut at rear of rod anti-clockwise, and vice versa. Toggle levers : distance between thrust faces and flywheel face to be set to 1.729 + .010 in. , 1.729 - .000 ; see "Special Service Pointers".
Linings. - Two, O.D. 9 in. ; total area 64.8 sq. in. ; thickness of lined plate, new .330 in., fully worn .210 in. (under load). Maximum permissible run out of lined plate : .010.in.
Withdrawal. - By bearing, sleeve and flanged thrust cup bushed on gearbox clutch shaft ; bearing and withdrawal fork enclosed in housing bolted to front face of geargox in bell ; bearing pressed on rear end of sleeve, lubricated from geargox, front of sleeve carries spherically-mounted spring loaded flanged thrust cup contacting toggle levers ; housing oil-baffled by scroll, excluder plate and drain hole.
Lubrication. - Pedal shaft, by grease nipple.
Electrical Equipment
Units. - See "Electrical Equipment and Test Data" Automobile Electricity Wiring Diagram D.529.
Engine
Type. - Four cylinder vertical water cooled with detachable head, overhead inlet valves and side exhaust valves.
Dimensions. - Bore : 69.5 mm. Stroke : 105 mm. Stroke/bore ratio : 1.51. Compression ratio : 6.8 : 1. Capacity : 1,595 c.c. Capacity of combustion chamber : 58.6 c.c.
Brake Horse Power. - 50-55 b.h.p. at 4,000 r.p.m.
Maximum Torque. - 80lbs./ft. at 2,000 r.p.m.
Rating. - R.A.C. : 11.98 h.p.
Suspension. - Four point rubber.
Valve Timing. - In degrees : inlet valve opens 9 degree B.T.D.C. and closes 45 degree A.B.D.C. : exhaust valve opens 42 degree B.B.D.C. and closes 16 degree A.T.D.C. Practical : flywheel marks, T.D.C. indicating No. 1 piston at T.D.C., G.P. indicating position of fully open exhaust valve (114 degree B.T.D.C) ; marks visible on removal of inspection cover at right hand side of flywheel housing. Timing chain ; duplex endless roller, pre-stretched, fitted with hydraulic tensioner ; pitch 3/8 in. ; number of pitcher 78.
Ignition Timing. - In degrees : 15 degree B.T.D.C. Practical : flywheel mark F.A. indicates firing point cf No. 1 cylinder. (Note. - Flywheels are common to Rover cars and Land-Rover and have three F.A. markings, at 7 degree, 11 degree and 15 degree B.T.D.C.). Set mark (15 degree) against pointer, octane selector in standard position and points just breaking with rotor arm pointing to No. 1 electrode.
Rocker Shafts. - Inlet : overhead, hollow, carried in three brackets, located by drilled setscrew in rear bracket ; diameter .4995 in. - .001 in. Exhaust : two, hollow, above camshaft, located by setscrews accessible on removal of side rocker cover; removed with extractor from rear after removal of toe-board, gearbox cover, distributor housing locating screw and plug and fibre washer, sealing rear end ; diameter, .593 in. - .001 in.
Rockers. - Inlet : off-set left and right, push rod operated ; bushed. Bushes flanged at one end ; I.D. .500 in. + .001 in. ; running clearance .001 in. to .003 in. Exhaust : off-set right and left, 1st, 4th, 5th and 8th operate exhaust valves, remainder operate push-rods for inlet valves ; bushed. Bushes : I.D. .593 in. + .001 in. For assembly order see "Special Service Pointers".
Valves. - Head diameter : inlet 1.703 in. - .004 in., exhaust 1.265 in. - .004 in. Stem diameter : .343 in. - .001 in. Overall length : inlet 4.684 in. - .004 in. ; exhaust 4.643 in. - .004 in. Seat angle : inlet 30 degree ; exhaust 45 degree, Guides : detachable, tapered bore ; O.D. .565 in. - .001 in. ; I.D. (head end) .3438 in. + .001 in. ; I.D. (outer end) .3432 in. + .001 in. ; length, inlet 1.968 in. - .016 in., exhaust 2.250 in. - .016 in.
Valve Springs. - Two per valve, selective assembly to give no diametral clearance between inner and outer. Replace in pairs. Internal diameter of outer springs : .857 in. + .005 in. Outside diameter of inner spring : .857 in.. + .005 in. Free length : inner 1.817 in. ; outer 1.845 in. Fitted length : (valve closed) inner 1.469 in. at load of 10 lbs. + 1/2 lb. and load of 10 lbs. - 1/2 lb. ; outer 1.625 in. at load of 30 lbs. + 1 lb. and load of 30 lbs. - 1 lb. Fitted length (valve open) : inner 1.193 in. at load of 17.97 ; outer 1.349 in. at load of 67.6 lbs. + 2 lbs. and at load of 67.6 lbs. - 2 lbs.
Pistons. - Type : Specialloid S132, tin plated or Lo-Ex alloy. Dimensions : diameter at bottom of the skirt at right angles to gudgeon pin 2.7347 in. - .0006 in. ; clearance at bottom of skirt at right angles to gudgeon pin .0009 in. to .0025 in. ; gudgeon pin boss bore .6872 in. to .6874 in. in. Fit : selective assembly to give clearance at bottom of skirt on thrust faces of .001 in. to .0015 in. ; clearance checked with .0015 in. feeler between inverted piston and cylinder wall, feeler to become tight fit with about 1/2 in. of skirt protruding above the bore. Rings : two compression and two scraper all above gudgeon pin. Width : compression .70 in. to .069 in. ; scraper .156 in. to .155 in. Radial thickness : compression .111 in. to .105 in. ; scraper .105 in. to .009 in. Fitted gap : comptession .014 in. to .018 in. scraper .011 in. to .015 in. Side clearance in groove : compression .0018 in. to .0038 in. ; scraper .002 in. to .004 in. Gudgeon pin : selective fit, cold and dry to require slight hand pressure but will not fall out under own weight ; pistons must not be reamed ; O.S. + .001, + .003 in. O.S. assemblies : + .010, + .020, + .030 and + .040 in.
Cylinder Block. - Material : cast iron. Bore offset : nil. Brimochrome exhaust valve seat inserts, diameter : 1.382 in. - 1. Reconditioning : maximum permissible rebore size (+ .040 in.) 2.7762 in. ; maximum permissible bore misalignment .005 in per in. Cylinder head : detachable inclined face 22 degree ; secured with 16 studs and jointed with copper asbestos gasket, thickness, normal .037 in., white metal lined and located by dowels ; centre takes thrust through integral flanges ; caps and housings numbered on front sides, shells marked with number or chisel to correspond with housing marks ; bearing dimensions, length, front, 1.687 in. to 1.682 in., centre 1.998 in. to 1.9965 in., rear 1.687 in. to 1.682 in. ; thickness .12525 in. to .125 in., running clearance .0013 in. to .0035 in. ; housing I.D. 2.2518 in. + .001 in. ; bearing nip .0015 in. to .002 in. ; nut tension 120 ft./lbs. Camshaft bearings : 3, split "Mazak", halves dowelle 1 together, located by set screws accessible on removal of side rocker cover ; rear end sealed by cover plate, plate secured by three set screws ; bearing demensions, O.D. 1.68725, 1.6865 in. *, I.D. .865 in., .875 in.*, length, front 1.875 in. - .008 in., others .937 in. -.008 in., housing diameter 1.6875 in. + .0005 in., running clearance .001 in. to .0025 in.
Connecting Rods. - Types : H section ; floating gudgeon pin ; offset : nil. Distance between centres : 7.875 in. + .002 in. and -.002 in. Big-end bore (base) : 2.0205 in. + .001 in. Small-end bore (base) : .812 + .001 in. Width at big end : 1.336 in. - .002 in. Width over gudgeon pin bcss : 1.062 in. - .008 in. Big ends : shimless white metal lined steel shells ; dimensions, thickness .07225 in., .072 in.*, width 1.178 in. 1.173 in., running clearance .001 in. to .0035 in., float (controlled by rod faces) .009 in. to .013 in. Small-end bush : I.D. .6875 in. - .004 in.; length 1.062 in. + .0005 in.
Crankshaft. - Drop forging ; counterbalanced and fitted with vibration damper at front ; lipped oil seal and thrower at front, cork seal and oil collector housing at rear. Journal dimensions : diameter 2.0000 in. + .00075 in. ; width, front 1.812 in. ; centre 2.000 in. + .0002 in. ; rear 1.796 in. + .008 in. Crankpin dimensions : diameter 1.875 in. - .001 in., width 1.375 in. + .002 in., radius .80 in. + .10 in. Regrind sizes : - .015 in., - .030 in., - .040.in.
Camshaft. - Journal dimensions : diameter .875 in. ; length, front 1.875 in., others 15/16 in. End float : .003 in. to .005 in., controlled by thrust plate on front face of cylinder block. Drives : one, centrally disposed integral helical for oil pump and distributor.
Lubrication. - By pressure from submerged gear type pump, vertical, spigoted in left hand side of crankcase and retained by square headed setscrew below side rocker cover. Pump : length of pump wheels 1.341 in. + .000 in., - .001 in. ; diameter of pump wheels 1.699 in. + .000 in., -.001 in. ; depth of cover 1.343 + .002 in., - .000 in.; bore of cover 1.700 in. + .002 in. - .000 in. ; end float of wheels .000 in. to .003 in. ; radial clearance between wheels and housing .001 in. to .004 in. ; diameter of idler wheel bush .500 in. + .001 in. ; diameter of pump body bush .5625 in. + .001 in. Pump drive : by independent vertical shaft carrying pinned helical for engagement with camshaft, splined at lower end for pump engagement. Pump suction : through 40-mesh gauze filter screwed into right-hand side of sump ; filter must be removed before attempting to remove the sump. Pump delivery : direct to main gallery, main and camshaft bearings, through drilled crankshaft to big-end bearings, and through drilled big-ends to cylinder walls ; timing chain supplied from front camshaft bearing and through holes in jockey pulley from hollow spindle ; inlet rockers supplied through external pipe from rear of gallery, exhaust rockers and inlet cam followers through drillings from centre camshaft bearing splash and leak off supplies gudgeon pins. Filter : external by-pass type, renew unit every 10,000 miles (road work), or every 300 hours (field work). Pressure relief valve : ball and spring, externally adjustable, located on left hand side below side rocker cover ; spring free length 2.750 in., number of coils 23, test length 1.827 in. at load of 9 lbs. ; set to give 40 lbs./sq. in. at 30 m.p.h using slave pressure gauge screwed in place of oil warning light adaptor. Sump : internally baffled ; capacity 10 points. Oil level : to dipstick on right hand side of engine ; dipstick marked "H" (normal level) and "L" (minimum level).
Cooling. - By thermo-syphon supplemented by impellor pump, thermostat control and fan. Pump : secured to front of cylinder block by eight set bolts and driven in tandem with fan by endless Vee belt from pulley on crankshaft, belt also drives dynamo. Pump gland : rubber seal and carbon thrust ring with spring at rear end of spindle. Pump impellor : pressed on spindle to give .020 in. clearance between vanes and pump casing face ; impellor bore .500 in. + .0005 in. O.D. of spindle : .5016 in. - .0005 in. giving interference fit of .0004 in. to .0016 in. Pump spindle : runs in double row ball bearing assembly, bearing aassembly located by setscrew in top of housing. Thermostat : non-adjustable, secured to cylinder head by four set bolts ; connected to pump by short copper tube and rubber ring ; operating temperature 167 degree - 190 degree F. Total capacity : 17 pints. Drainage points : two, tap on right hand side of cylinder block, and tap below radiator. Fan : four-bladed, mounted on pump spindle and secured by four set bolts. Belt adjustment by slotted dynamo anchorage, tension correct when deflection is 1/2 to 1 in. Lubrication : bearing assembly pre-packed with high melting point grease. Starting : by flange mounted starter at left hand side rear end of crankcase ; sliding pinion engagement. Flywheel teeth : 97, integral with flywheel. Starter pinion teeth : 11. Drive ratio : 8.81 : 1.
Front Axle
Type. - Live ; banjo case ; fully floating ; spiral bevel drive ; front cover welded on ; constant velocity joint at each end.
Pinion Shaft Location. - By double row semi-thrust ball bearing in detachable housing at front ; parallel roller bearing at rear. Front bearing : inner ring secured between universal joint flange and distance tube ; outer ring secured between rebate in housing and ene cover containing oil seal. Rear bearing : inner ring secured between distance and pinion ; outer ring secured between two spring rings.
Crown Wheel Location. - By two taper roller bearings one each side of differential ; inner rings pressed on to spigots on differential cage ; outer rings secured in splithousings and located by adjusting rings locked by tabs.
Axle Shafts. - Claws formed at outer ends to engage with tracta joint splined at inner ends to engage differential pinions. Location : by grease packed ball bearing in seivel pin bearing housing ; bearing light press fit on shaft ; outer ring retained by rebate at outer side and flange of axle tube at joint between tube and swivel pin beating housing ; inner ring retained by collar presseed on shaft. Dimensions : bearing O.D. 3.000 in. - .0008 in. and - .0013 in. ; housing I.D. 2.9995 in. + .001 in. ; bearing I.D. 1.375 in. + .002 in. and - .0003 in. ; diameter of shaft 1.3758 in. - .0005 in. Drive shafts : claw formed at inner ends for engagement with tracta joint, splined at outer end to engage with hub driving member.
Stub Axle and Swivel Pin Assemblies. - Male hemi-spherical swivel pin bearing housing flange bolted to axle tube with internal and external oil seals at junction ; housing carries two taper roller bearings, one at top and one at bottom. Female hemi-spherical housing carrying swivel pins, fitting over swivel pin bearing housing enclosing tracta joint ; outer face bolted to stub axle. Swivel pins : two part ; top, integral with steering arm, lower, integral with plate ; each secured to housing with four nuts and studs. Stub axles : hollow ; flanged and rebated at inner end, threaded at outer ends for hub nuts ; internally bushed at inner ends for drive shafts.
Adjustment. - Pinion shaft preload setting : by shims between front bearing housing flange and flange of oil seal retainer ; measure amount by which bearing stands proud of its housing (usually .007 to .012 in. ) and add shims so that when assembled bearing is punched to an extent of .003 to .004 in. in the case of Skefco and Fischer bearing, or .0045 to .0055 in. in th case of the Hoffman split type bearing. Pinion to crown wheel : by shims between bearing housing and pinion shaft housing. See "Special Servide Pointers". Crown wheel bearings and crown wheel to pinion : by adjusting rings either side of differential assembly ; one serration movement of adjusting rings equal to app. .005 in. axial movement. Meshing check : see "Special Service Pointers". Backlash : .007 in. Swivel pins : bearings, interference fit of .0005 in. to .0021 in. in housing ; swivel pins .0003 in. to .0014 in. clearance fit in bearings. Swivel pin bearing pre-load : .005 in. obtained by shims between stub axle plated and housing ; remove shims till up and down movement of swivel pin housing is zero. then remove .005 in. shim from one swivel pin ; shim thickness to be shared equally between the two swivel pins of each assembly. Hub float : .003 in. to .004 in., checked with dial indicator and adjusted by nut and locknut on stub axle.
Lubrication. - Differential : to filler plug at front of banjo case ; capacity 3 pints. Tracta joints : to filler plug at rear of joint housings ; capacity 1 pint (each joint).
Gearbox
Type. - Independent main box arranged for assembly with transfer box, freewheel, clutch housing and engine forming single unit.
Speeds. - Main box ; four reverse, with synchromesh engagement on top and 3rd, constant mesh helical with sliding dog engagement on 2nd. Transfer box : high, constant mesh. Ratios : main box. 1st, 2.996 : 1 ; 2nd, 2.043 : 1 ; 3rd, 1.490 : 1 ; 4th, (top) 1 : 1 ; transfer box, high, 1.148 : 1 ; low, 2.888 : 1, giving eight forward and two reverse.
Gear Wheels. - Main box : 3rd and 2nd, single helical ; remainder, straight spur. Transfer box : high, single helical ; remainder, straight spur. Speedometer drive : worm and pinion arranged at right angles ; located at rear of transfer box.
Main Line. - Clutch shaft bearing : deep groove ball in bell housing ; outer ring located by housing rebate at front and bolted retainer plate at rear ; inner ring pressed on shaft, retained at front by nut and lock washer, at rear by constant mesh pinion. Dimensions : bearing O.D. 3.250 in. - .0008 in., -.0013 in., housing bore 3.248 in. + .001 in. Spigot bearing : needle roller. 2nd and 3rd speed gears : on centrally flanged sleeve pegged to thrust washer at rear ; thrust washer and spring at front of 3rd locates assembly ; end float of 2nd and 3rd gear assembly .002 in. to .004 in. controlled by thickness of thrust washer ; thrust washer thickness available .125 in., .128 in., .135. and .138. Main box rear bearing : deep groove ball press fit in pegged housing, retained by circlip, inner ring secure on shaft by 1st speed splines at front and distance piece, main transfer gear and retaining nut at rear ; bearing housing push fit in gearbox rear end ; bearing housing O.D. 3.5000 in. - .0005 in., gearbox casing bore 3.5000 + .0005 in. Rear end of mainshaft extends into transfer box, supported in needle roller bearing ; bearing in detachable housing bolted to rear of transfer box ; when P.T.O is fitted it replaces this housing.
Countershaft Line. - Front bearing : deep groove ball, located on shaft by nut and washer at front, and distance piece and shoulder at rear ; press fit on shaft. Dimensions : bearing bore 1.500 in. + .0002 in., - .0003 in. diameter of shaft, 1.500 in. - .0005 in. giving interference .0003 in. to clearance .0007 in fit. Constant mesh and 3rd speed helical splined on shaft and separated by sleeve, 2nd speed gear located at rear by split ring in groove in shaft and inside gear flange. Rear bearing : single row roller, tap fit on shaft. Dimensions : bore .875 in. + .0002 in., - .0003 in. shaft diameter, .8755 in. - .0005 in. giving interference .0008 in. to clearance .0002 in. fit ; outer ring drive fit in blind hole, lipped edge to rear, casing bore 1.998 in. + .001 in., diameter of race 2.000 in. - .0005 in., -.001 in. giving zero to .0015 in. interference fit.
Reverse Cluster. - Gears bushed ; ream to .8125 in. + .001 in. ; shaft, drive fit in housing, bore of housing .500 in. - .001 in., diameter of shaft .5015 in. -.001 in.
Intermediate Gearing (Main to Transfer). - Shaft : light tap fit in casing, retained by bolted retainer plate at rear ; diameter of shaft 1.140 in. - .0005 in., casing bore 1.140 in. + .0005 in. Gear cluster : on two needler roller bearings, located between two thrust washers ; end float .005 in. to .010 in.
Transfer Box. - Bolted to rear of main box, at right angles ; housing for freewheel and front output drive at front, housing for speedometer drive, transmission brake assembly and rear output drive at rear. Provision at rear behind main box main shaft and on top for fitting P.T.O.s. Bearings, gears and shaft : shaft splined at front to drive freewheel locking dog drive gear ; taper roller bearing in rear of casing retained by circlip drive fit in casing, light press fit on shaft ; bearing O.D. 2.717 in. + .0006 in., casing bore 2.7159 in. + .0005 in., bearing bore 1.375 in. + .0005 in. ; high speed helical free on shaft in permanent engagement with intermediate high speed gear, end float .006 in. to .010 in. controlled by thickness of thrust washer between high and low speed gears ; low speed gear splined on shaft sliding dog engagement with high speed gear ; rear taper roller bearing located by front face of speedometer frive housing drive fit in casing ; bearing O.D. 3.151 in. + .0006 in., fit on shaft as for front bearing ; shaft end float, zero, controlled by shims between casing and speedometer drive housing.
Transfer and Output Shafts. - Types : two ; type one, from Vehicle number 860001 to 861988, type two, from Vehicle number 861989 onwards. Type one : two part, front portion splined for engagement with driving flange inner end dogged and spigotes in rear portion ; rear portion externally splined for loking dog, flange bolted to freewheel outer housing. Bearings : front, ball, drive fit in casing retained by circlip and rebate in front end of transfer shaft case ; bearing O.D. 2.717 in. + .006 in., bore of casing 2.7159 in. + .0005 in. ; bearing I.D. 1.250 in. + .0002 in., -.0003 in. shaft O.D. 1.2505 in. - .0005 in. ; oilite spigot bush : rear, ball, push fit in front face of free wheel case, retained by circlip and rebate in casing ; bearing O.D. 3.5000 in. - .0008., -.0013 in. ; bore of casing 3.4995 in. + .0005 in. ; bearing I.D. 1.625 in. - .0003 in. ; shaft O.D. 1.6254 in. - .0005 in. (light press fit ). Type two : one piece shaft splined at front end for engagement with driving flange flange-bolted to freewheel outer member at rear ; bearings, front ball, drive fit in housing ; bearing O.D. 2.717 in. + .0006. Bore of case : 2.7159 in. + .0005 in. ; bearing I.D. 1.250 in. + .0002 in., - .0003 in. shaft O.D. 1.2505 in. - .0005 in. ; rear, as for type one. Freewheel assembly : Rover. Operates on front drive only ; locked for four-wheel drive in reverse by pull up ring control.
Change. - Main box : 1st, left forward ; 2nd, left back ; 3rd, right forward ; 4th (top), right back ; reverse, full left against spring and forward. Transfer box : low, back ; neutral, central ; high, forward. N.B. - "high" to "low" only when vehicle is stationary.
Ratios. -