An internal oilway from the camshaft front bearing connects the cylinder block to the cylinder head and feeds oil to the rocker shaft assembly (10), lubricating the valves and springs. The pistons, gudgeon pins and small end bushes are lubricated and cooled by oil jets (11) which are supplied from the main oil gallery via relief valves which allow the oil to flow at a pre-determined pressure. Oil pressure is controlled by a pressure relief valve (12) incorporated in the timing case housing together with the oil pump. The valve allows excess oil to be recirculated back into the oil feed gallery.

The rotor type oil pump is driven by 2 flats Range Rover machined on the front of the crankshaft. Oil cooling is maintained by an oil cooler which is integral with the radiator and linked to adaptors on the oil filter head by pre-formed feed and return hoses. A thermostatic valve in the filter head allows oil to flow to the cooler when it reaches a pre-determined temperature.

Crankcase ventilation system. A breather cyclone unit (1), fitted to the right hand side of the rocker cover controls the rate at which air is purged from the sump, via a hose (2) from the camshaft side cover to the rocker cover and extracts oil from the gaseous atmosphere. The oil then drains back to the sump through a hose and flanged pipe connection (3). The residues are drained-off from the top of the cyclone breather and pass through a hose (4) into the engine via the turbocharger where they are burned in the combustion chamber.

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This Manual does not constitute an offer for sale of any particular component or vehicle. Rover/Land Rover Dealers are not agents of Rover/Land Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.

GEARBOX IDENTIFICATION The procedures given in this manual cover overhaul of the R380 gearbox fitted to a range of vehicles and as such, certain differences exist between gearboxes, particularly in respect of the extension housings, gear change housings and transfer box selector housings. It is important therefore that before starting work, the gearbox to be overhauled is correctly identified. Identification can be made by noting the gearbox serial number prefix stamped on the RH side of the gearbox casing and referring to the following table which lists four types of gearbox, A, B, C and D together with their appropriate serial number prefixes.

The R380 5 speed all synchromesh gearbox comprises an input shaft, output shaft, layshaft and reverse idler shaft. Gearbox casings consist of a front cover, gearcase, centre plate and extension housing, all casings are located by dowels and sealed. Selector forks for 1st/2nd and 3rd/4th gears are located on a single selector shaft inside the main gearcase whilst the selector fork for fifth and reverse gear is located on the same selector shaft inside the extension housing.

The input shaft, output shaft and layshaft are supported by taper roller bearings with all gears running on caged needle roller bearings. Output shaft and layshaft bearings end float is controlled by selective thrust washers located in the centre plate. Lubrication is by an oil pump located in the extension housing which directs oil via internal drillings in the output shaft to lubricate the components.

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Adapter installation Locate appropriate wires on a car stereo harness (refer diagram above) Snap T-Tap clip over the wire so it is fastened. Now you can attach male terminal to an appropriate T-Tap according to the harness diagram and color of the adapter wire. Use 10 pin black connecter (audio cable) coming out of adapter and attach it as shown on a diagram above to the car stereo (shown as dotted rectangle with ”+‘ signs).

Note : Make sure the white stripe on the black connector is looking up ! Find a place where you can place Car2PC. In all BMW/Mini there is enough room inside the dash to place Car2PC. Note : Make sure you place Car2PC in a place with enough room so when you mount car stereo back you do not break the adapter.

You may use glove box or other spaces on a dash to direct USB+ Audio cables to Mount your car stereo back into the dash, make sure it‘s clips are securely fastened. Now you can turn you car stereo on and switch it over to CD Changer mode. It should show Disk 1, Track 01 on a display. If it is not -see Troubleshooting section. Congratulations ! You have installed Car2PC adapter and you may use it right now either as AUX input for any multimedia player or use it with your PC/laptop.

Driver installation Make sure you turn your car stereo on Connect USB cable to your PC/laptop Upon connection PC if it runs Windows 2000 or XP will prompt. Insert driver‘s disk into CD drive and click Next. When Windows comes up with the message below, just click —Continue Anyway“button…

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Since 1958 there have been three basic chassis lengths, about half a dozen different engines and dozens of permutations of seating, loadspace and window arrangement to choose from. Thanks to the bolt-together modular construction of Land Rovers, it can often be easier to modify an existing vehicle to suit your requirements than to try and find one which already meets them. That is why, before I even think about showing you any vehicles for sale, I like to understand what you will be asking your Land Rover to do.

Towing a horsebox? Camping holidays? Offroad adventures? Carrying two people, or twelve? Long distances, or just local trips? The more information you can give me, the better. There are many myths surrounding Land Rovers, so let’s demolish a few of them at this stage. For some reasons please read complete this PDF guide for your information…

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Whenever Defender Models are parked for extended periods (14 days or over), batteries should be disconnected since battery isolator is not fitted. The correct tools must always be used. Only trained personnel should be authorised to undertake this activity.

Defender battery reconnections should be to correct Torque levels. Voltage checks should be undertaken before the battery is reconnected. Once Defender battery reconnected, key fob will need to be re synced by pressing the unlock button 3 rimes – the indicators will flash as per a normal unlock when the process is complete. The radio code will also be required to be inputted again. If defender is in storage for more than 90 days, after battery disconnection, vehicle is to be reconnected and run to engine is warm and voltage checked.

Replacement of batteries.
Ensure that correct battery type is requested. Confirm type is correct on receipt of a battery from store. For removal purposes, first disconnect the negative, then the positive terminal of the battery. For installation / reconnection, apply the reverse sequence, i.e. first the positive terminal, then the negative terminal. Terminals should be tightened to factory torque settings.

A lifting device is recommended to assist battery removal and operative safety in the event of multiple changes being required. Operative safety is a primary consideration at all times. When storing batteries it is essential that they comply with Health and Safety requirements as stipulated by your Health and Safety Manager. Scrap batteries must be returned to plant MP&L for the safe and controlled disposal in line with environmental guidelines.

6.6 Loose Item checks.
The following items should be checked at each and every receipt or contract transfer, irrespective of location. They form a core part of any survey checks undertaken. Vehicles should be checked (subject to market standard items) and can include the following items: -

Two sets of keys / infrared sensors
Spare wheel and tools
ICE /Sat Nav present
Vehicle protection in place

Items in secure areas /sealed / under bonnet or where removal of seats would be needed to be made to confirm their presence and are specifically excluded in respect of TRANSIT checks. If broken seals are noted then this condition should be recorded to history record, VLDR or tracking system and reported to JLR.

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The centrally located camshaft is driven by the crankshaft via a chain. The valves are operated by rockers, pushrods and hydraulic tappets. Exhaust valves used on later engines are of the ’carbon break’ type which incorporate a machined undercut at the combustion chamber end of the valve. The design prevents carbon build-up on the valve stem which could lead to valves sticking. These valves are interchangeable with valves fitted to early engines.

Each of the aluminium alloy pistons has two compression rings and an oil control ring. The pistons are secured to the connecting rods by semi-floating gudgeon pins. The gudgeon pin is offset 0.5 mm (0.02 in), identified by an arrow mark on the piston crown, which must always point to the front of the engine. Plain, big-end bearing shells are fitted to each connecting rod.

Lubrication

The full flow lubrication system uses a gear type oil pump driven from the crankshaft. The assembly is integral with the timing cover which also carries the full flow oil filter, oil pressure switch and pressure relief valve. Oil is drawn from the pressed steel sump through a strainer and into the oil pump, excess pressure being relieved by the pressure relief valve. The oil pressure warning light switch is screwed into the timing cover and registers the oil pressure in the main oil gallery on the outflow side of the filter.

Pressurised oil passes through an oil cooler mounted in front of the radiator to the full flow oil filter. The oil then passes through internal drillings to
the crankshaft where it is directed to each main bearing and to the big end bearings via numbers 1, 3 and 5 main bearings. An internal drilling in the cylinder block directs oil to the camshaft where it passes through further internal drillings to the hydraulic tappets, camshaft journals and rocker shaft. Lubrication to the thrust side of the cylinders is either by oil grooves machined in each connecting rod big end joint face or by splash.

Clip
Pushrod seat
Inner sleeve
Upper chamber
Non-return ball valve
Spring
Outer sleeve
Lower chamber

The purpose of the hydraulic tappet is to provide maintenance free and quiet operation of valves. It achieves this by utilising engine oil pressure to eliminate the mechanical clearance between the rockers and the valve stems. During normal operation, engine oil pressure, present in the upper chamber, passes through the non-return ball valve and into the lower chamber. When the cam begins to lift the outer sleeve, the resistance of the valve spring, felt through the push rod and seat, causes the tappet inner sleeve to move downwards inside the outer sleeve. This downward movement of the inner sleeve closes the ball valve and increases the pressure in the lower chamber sufficiently to ensure that the push rod opens the valve fully.

As the tappet moves off the peak of the cam, the ball valve opens to equalise the pressure in both chambers which ensures the valve closes when the tappet is on the back of the cam.

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Rear Air Spring Removal:
1. Raise the rear suspension of the vehicle with proper lifting equipment. Both wheels must be off the ground with no load. ALWAYS USE EXTREME CAUTION WHEN LIFTING VEHICLE! (Refer to shop manual for lifting instructions)
2. Remove both rear wheels.
3. Depressurize air spring by removing nylon air hose. To remove air hose, push down on the metal collet, while pulling out on the hose.
4. Remove top air spring clip.
5. Remove lower air spring securing clip.
6. Remove and discard old air spring.
7. Remove retaining nuts from both rear shocks.
8. Install coil spring onto rear suspension. Align the upper aluminum spring mount in place.
9. Hold the coil spring against the upper mount, while sliding lower spring perch into place.
10. Using a floor jack, jack up the axle, compressing coil springs so you can replace lower shock retaining nuts
11. Replace wheels and lower vehicle.

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TO CONTINUE A CONVERSATION WHEN EXITING THE VEHICLE
1. Exit vehicle
2. Phone will advise that “Hands free device has failed” (Bluetooth™ connection)
3. Phone will display “Would you like to continue conversation”
4. Select “Yes” on handset
5. Continue talking using handset
TO CONTINUE A CONVERSATION WHEN ENTERING THE VEHICLE
1. Enter vehicle
2. Start engine
3. Select “I agree” on navigation screen
4. Vehicle navigation screen will display “Bluetooth™ Connection Successful”
5. Continue talking hands free

INITIAL INSTALLATION
1. Menu
2. Toggle to “Connect ”
3. Push down on joystick to select
4. Toggle to “Bluetooth™”
5. Push down on joystick to select
6. Toggle to “Mode”
7. Push down on joystick to select
8. Select “On”
9. Select “Discover”
a. All available devices will appear
on screen
10. Scroll to desired device
11. Push down on joystick to select
12. Select “Add to Paired”
13. Push down on joystick to select
14. Enter pass code: 1212
15. Press Select
16. Select Name
17. Select “Ok”
18. Screen will display “Add Device”
19. Scroll to desired device (hands free)
20. Push down on joystick to select
21. Scroll to “Connect”
22. Push down on joystick to select
23. Device is now connected
24. Press and hold back button for 2 seconds to return to main menu

TO CONTINUE A CONVERSATION WHEN EXITING THE VEHICLE
1. Exit vehicle
2. Phone will advise that “Hands free device has failed” (Bluetooth™ connection)
3. Phone will display “Would you like to continue conversation”
4. Select “Yes” on handset
5. Continue talking using handset

TO CONTINUE A CONVERSATION WHEN ENTERING THE VEHICLE
1. Enter vehicle
2. Start engine
3. Select “I agree” on navigation screen
4. Vehicle navigation screen will display “Bluetooth™ Connection Successful”
5. Use handset toggle to “Connect”
6. Toggle to “Bluetooth™”
7. Push down on joystick to select
8. Toggle to “Transfer Sound”
9. Push down on joystick to select
10. Scroll to desired device (hands free)
11. Phone will display “Connecting”
12. Device is now connected

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