Systems Covered:
Engine (including TDI), Fuel System (TDI), Cooling System (TDI), Manifold and Exhaust, Clutch, Manual Gearbox, Transfer Gearbox, Propeller Shafts, Rear Axle and Final Drive, Front Axle and Final Drive, Steering, Front Suspension, Rear Suspension, Brakes, Wheels and Tyres, Chassis and Body, Heating and Ventilation, Air Conditioning, Wipers and Washers, Electrical Systems, Instruments
Procedures Included:
Step-by-step repair instructions, troubleshooting, maintenance procedures, rebuilding procedures, refurbishment techniques, restoration guidance, exploded diagrams, illustrations, wiring schematics
Technical Depth:
Advanced diagnostics, complete mechanical and electrical repair, overhaul procedures, component replacement, tuning, fluid level checks and changes, suspension alignment, brake bleeding, electrical system troubleshooting
Engine Overhaul Procedures:
Complete engine disassembly, inspection, component replacement (pistons, rings, bearings, valves), cylinder head and block machining specifications, timing belt/chain alignment, engine reassembly.
Transmission Overhaul Procedures:
Detailed steps for gearbox and transfer case disassembly, gear inspection, bearing replacement, synchromesh repair, shaft alignment, clutch assembly, and reassembly.
Brake System Procedures:
Front disc brake and rear drum brake inspection, pad/shoe replacement, caliper/wheel cylinder overhaul, brake line replacement, brake bleeding procedures, master cylinder overhaul.
Electrical System Procedures:
Wiring diagrams for all circuits (lighting, ignition, starting, charging, instruments), troubleshooting guides for electrical faults, component testing (starter motor, alternator, ignition coil, light bulbs).
Chassis And Body Procedures:
Frame inspection and repair, body panel removal and installation, door and hinge adjustments, seat mounting, tailgate operation, weather stripping replacement.
Suspension And Steering Procedures:
Front and rear leaf spring inspection and replacement, shock absorber replacement, kingpin overhaul, steering box adjustment and replacement, tie rod end replacement, wheel bearing adjustment and replacement.
Technical Specifications Details:
Torque specifications for all major fasteners, engine tuning data (ignition timing, valve clearances, carb settings), suspension alignment angles, brake system clearances, wheel bolt pattern (e.g., 5x165.1 mm).
Troubleshooting Guides:
Diagnostic tables for common engine, fuel, ignition, electrical, and drivetrain problems with suggested solutions.
Restoration Tips:
Guidance on originality, sourcing parts, and techniques specific to preserving or restoring a Series III to factory condition.
Primary Engine:
2.25 Litre (2286 cc) Naturally Aspirated Four-cylinder petrol engine
Alternative Engines:
2.25 Litre (2286 cc) Naturally Aspirated Four-cylinder diesel engine, 3.5 Litre (3528 cc) V8 petrol engine (optional on later Series III Stage 1 V8 models).
Performance 2 25 Petrol:
Approx. 68 hp @ 3500 rpm, 175 Nm torque @ 2000 rpm (figures may vary slightly by year).
Performance 2 25 Diesel:
Approx. 62 hp @ 4000 rpm, 130 Nm torque @ 2000 rpm (figures may vary slightly by year).
Performance 3 5 V8:
Approx. 110 hp @ 3500 rpm, 250 Nm torque @ 2500 rpm (figures may vary slightly by year).
Fuel System Petrol:
Single Zenith, Solex, or Stromberg carburetor (model dependent); Lucas or CAV fuel pump.
Fuel System Diesel:
Lucas CAV fuel injection pump, Simms fuel injection pump (early).
Ignition System:
Distributor-based, coil ignition system.
Cooling System:
Pressurized coolant system with fan-assisted radiator.
Oil Change Interval:
Every 3,000 miles (4,800 km) or 6 months for engine oil and filter.
Gearbox Oil Change Interval:
Every 12,000 miles (19,200 km) or 12 months for transmission and transfer case oil.
Axle Oil Change Interval:
Every 12,000 miles (19,200 km) or 12 months for front and rear axle differentials.
Engine Oil Specification:
API SF/CD, SAE 20W-50 (or 10W-40 for colder climates).
Gearbox Oil Specification:
GL-4, SAE 80W-90 gear oil (or specialist 'EP90' oil).
Axle Oil Specification:
GL-4, SAE 80W-90 gear oil (or specialist 'EP90' oil).
Coolant Specification:
Ethylene glycol-based antifreeze with water (50/50 mix).
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues:
Rust on body panels and chassis, gearbox synchromesh wear (especially on early Series III), leaky seals and gaskets, dashboard electrical reliability, exhaust manifold cracking (especially on 2.25 petrol).