Land Rover Defender 90 1993 User Manual

DEFENDER

WORKSHOP

PART

1

DATA AND MAINTENANCE

SECTION Introduction SECTION General Specification Data

SECTION Engine Tuning Data.............................................

SECTION Torque Wrench Settings........................................

SECTION General Fitting Instructions................................

SECTION Recommended Lubricants, Fluids

SECTION Maintenance.......................................................

2.

ENGINE AND ENGINE SYSTEMS

SECTION Engine SECTION Fuel System

SECTION Cooling SECTION Manifold and Exhaust

SECTION Clutch...............................................................

MANUAL

....................................................

................................

and Capacities...................................................

.............................................................

.....................................................

System..............................................

........................................

3.

TRANSMISSION

SECTION Manual Gearbox...............................................

SECTION Transfer Gearbox SECTION Propeller Shafts

SECTION SECTION

4.

CHASSIS AND

5.

AIR CONDITIONING AND ELECTRICAL EQUIPMENT

Published by Land Rover, Lode Lane, Solihull, West Midlands, B92 8NW. England.

BODY

SECTION Steering

SECTION Suspension SECTION Brakes SECTION Chassis and Body

SECTION Heating and Ventilation SECTION Air Conditioning SECTION Electrical Equipment

Front and Rear axle differentials

Front Axle and Final Drive...................................

..........................................................

...........................................................

...............................................

......................

....................................................

...........................................

......................................

..................................................

..........................................

Publication Part Number: LDAWMEN93US

©Land Rover

1993

Section

Number

PART

ONE CONTENTS

Page

01

04

INTRODUCTlON

•

Warnings and cautions

•

References

•

Dimensions

• Repairs and replacements

•

Fuel handling precautions

•

Recommended sealants

•

Poisonous and dangerous substances 3

•

Disposing of used oil and fluids 3

•

Accessories and conversions

•

Specification 4

•

Special service tools 5

•

Abbreviations and symbols

•

Location of vehicle identification and unit numbers 7

GENERAL SPECIFICATlON DATA

•

V8

engine data 1

•

Transmission

•

Propeller shafts 3

•

Suspension

•

Brakes 4

•

Steering

•

Electrical equipment

•

Replacement bulbs and units 6

•

Vehicle dimensions

•

Vehicle weights and payload 7

•

Wheels

•

Tire Pressures

and tires 8

1 1

1

2

4

6

3

4

5

7

8

06

ENGINE TUNING DATA

•

V8

engine tuning data 1

TORQUE WRENCH SETTINGS

•

Engine

•

Fuel lines

•

Clutch

•

Gearbox

•

Transfer box

•

Front axle

•

Rear axle and final drive 4

•

Propeller shafts

•

Rear suspension

•

Steering and front suspension

•

Power assisted steering 5

•

Brakes 5

•

Electrical 5

•

Air Conditioning

1

1 1 2

3

4

5

REISSUED: FEB

1993

PART

ONE

CONTENTS

Page

07

09

GENERAL FITTING INSTRUCTIONS

•

Precautions against damage

•

Safety precautions

•

Preparation

•

Dismantling

•

Inspection • general

•

Ball and roller bearings

•

Oil seals

•

Joints and joint faces

•

Flexible hydraulic pipes, hoses

•

Metric

•

Metric nut identification

•

Hydraulic fittings

•

Keys and keyways

•

Tab

bolt

identification

washers

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

1 1

1

2

2 2

3 3

4

4 4

5

6

10

•

Recommended lubricants

•

Anti-freeze

•

Capacities

MAINTENANCE

•

Workshop maintenance schedules

•

Lubrication

•

General maintenance and adjustment

1

2

3

1

9

12

REISSUED:

FEB

1993

Section

Number

PART

ENGINE

•

Description

•

Engine fault diagnosis

•

Engine removal

•

Engine dismantle and overhaul

•

Assembling engine

•

Service tools

TWO

CONTENTS

Page

1

7

11

13

31

49

EMISSION

•

Emission control

•

Crankcase ventilation system

•

Evaporative emission control

•

Fuel tank evaporative control

•

Evaporative purge system operation

•

Fuel tank evaporative control system operation

•

Fuel expansion tank - remove and refit

•

Heated oxygen sensor - remove and refit

•

Charcoal canister

•

Charcoal canister - purge valve - remove and refit

•

Positive crankcase ventilation

•

Air intake filter - remove and refit

•

Breather filter - remove and refit

•

Emission label

CONTROL

-

remove and refit

FUEL SYSTEM

-

Diagnostic equipment

•

Hot wire multiport fuel

•

Engine tuning

•

Multi meter checks

•

Multi

port

fuel injection • circuit diagram

•

Base idle speed setting

•

Fuel pressure check

•

Injector tests

•

Removing air cleaner

•

Removing mass air

•

Removing throttle

•

Removing idle air control valve

•

Removing vehicle

•

Removing fuel injection • relay modules

•

Removing inertia fuel shut-off switch

•

Removing engine fuel temperature sensor

•

Removing engine coolant temperature sensor

•

Depressurising fuel system 12

•

Removing fuel pressure regulator

•

Removing fuel rail - injectors

•

Removing plenum chamber

•

Removing ram housing

•

Removing intake manifold 19

•

Removing fuel filter

•

Removing fuel tank and fuel pump

•

Removing accelerator cable

•

Removing accelerator pedal

injection

flow

sensor

position

speed

sensor

r/h

and l/h

1 1

2

2 2

3

4

5 5

6 6 7

1

2

4 4

5

6

7

8

9 9

10

11

12

13

14

19

20

21

23

24

Section

Number

PART

COOLING SYSTEM

•

Engine protection

•

Drain and refill cooling system

•

Removing water pump

•

Removing thermostat

•

Removing radiator

•

Cooling system fault diagnosis

MANIFOLDS AND EXHAUST

•

Exhaust system complete

•

Exhaust system - remove and refit

•

Exhaust manifold - remove and refit

CLUTCH

TWO

CONTENTS

Page

1

2

4

5

1

2

3

•

Clutch assembly renewal

•

Clutch fault diagnosis

•

Clutch release bearing assembly - overhaul

•

Master cylinder - overhaul

•

Slave cylinder • overhaul

•

Clutch pedal adjustment

•

Bleed clutch hydraulic system

•

Renew clutch slave cylinder

•

Renew clutch master cylinder

1

2

3 3

5

6

7

8

Section

Number

PART

THREE

CONTENTS

Page

- Remove and refit

-

Overhaul 4

-

Data 41

-

Torque values 41

-

Service tools 42

-

Remove from

-

Overhaul

-

Torque wrench setting

-

Dismantle

-

Overhaul

-

Overhaul Rear hub assembly

-

Overhaul rear axle differential assembly (Salisbury) Defender

-

Overhaul rear axle differential assembly (Ninety) Defender

LT77S

gearbox

110

90

1

3

5

10

1

4

12

-

Overhaul Front hub assembly

-

Stub axle shaft, constant velocity joint and swivel assembly

-

Front axle differential

-

Dismantle

-

Inspection

-

Data

1 3

8

11

14

23

Section Number

PART

-

Overhaul steering column

-

Overhaul power steering box

-

Power steering system - Adwest lightweight box

-

Test equipment 22

-

Adjust power steering box - Adwest lightweight box

-

Pipe connections

-

Steering box sector shaft seal

-

Power assisted steering pump - overhaul

-

Power steering fault diagnosis

-

Overhaul drop arm bail joint

-

Track rod and draglink

-

Front wheel alignment

-

Overhaul rear suspension

-

Levelling unit - Functional check

-

Coil spring specification 2

-

Remove levelling unit

-

Panhard rod

-

Radius arm

-

Front shock absorber

-

Front road spring

-

Bump stop 8

-

Anti-roll bar front

-

Anti-roll bar ball joint links front

to

steering box 23

FOUR

CONTENTS

Page

1

7

21

22 23

24

29

30

32

1

2

3 6

6

7

8

9

10

-

Description

-

Overhaul front brake calipers

-

Overhaul rear brakes

-

Overhaul transmission brake

-

Bleeding the brakes

-

Renewing

-

Overhaul master cylinder

-

Renew master cylinder - Lucas Girling

-

Renew

-

Renew servo non-return valve

-

Renew brake servo

-

fault diagnosis

front

brake discs

-

Lucas

'G'

valve 16

Girling

2.4

mm AS/AS

mm

AS/AS

1

2 5

6

8

9

15

11

16

17 18

RE-ISSUED:

FEB

1993

Section Number

Page

-

Chassis alignment and squareness

-

Chassis dimensions Defender

-

Chassis dimensions Defender

-

Door

lock mechanisms Defender

-

Door

trim Defender

-

Window regulators - rear side doors Defender

-

Exterior handle - rear side door Defender

-

Door

locking button - rear side door Defender

-

Remote control lever - rear side door Defender

-

Door

latch assembly - rear side door Defender 110

-

Door

glass - rear side door Defender 110

-

Mounting panel - front doors Defender 110

-

Door

locking button - front doors Defender 110

-

Window regulators - front doors Defender 110

-

Remote control lever - front doors Defender 110

-

Exterior handle - rear side

-

Door

latch assembly - rear

-

Glass

-

front

doors

-

Locking barrel - front doors

-

Rear window side trim Defender

-

'B'

post trim Defender 110

-

Rear quarter light trim

-

Grab handles Defender 110

-

Door

lock, rear door Defender

110

Defender

110

90

110

door Defender 110

side door Defender 110

110

Defender 110

110

110, front and rear doors Defender 90

110

1

3

5

6 7 8 9

9

10

11

13

14

15

16

17

18

19

21

22

23

REVISED:

OCT

1993

Section

Number

PART

-

Remove. overhaul and

-

Introduction

-

Periodic Maintenance

-

Circuit diagram

-

Fault diagnosis

-

Charging and testing equipment

-

Depressurizing System 12

-

Evacuating

-

Sweeping 14

-

Charging

-

Leak test

-

Pressure test

-

Compressor - remove and refit

-

Drive belt adjustment

-

Condenser fan motors - remove and refit 17

-

Condenser and receiver/drier - remove and refit

-

Evaporator 19

-

Resistor block

refit

FIVE

CONTENTS

Page

1

2

5

6

11

13

15

16

17

18

22

-

Electrical precautions

-

Distributor - Lucas 35DLM8 remove and refit

-

Distributor - Lucas 35DLM 8 overhaul

-

Ignition timing adjustment

-

Electronic ignition - preliminary checks

-

Alternator -

-

Battery 9

-

Starter motor - Lucas M78R 10

-

Headlamps

-

Side, tail and flasher lamps

-

Rear number plate lamp

-

Rear lamps

-

Reverse light switch

-

Warning lamps

-

Instrument illumination

-

Wiper motor overhaul 18

-

Renew wiper motor and drive rack

-

Renew windscreen wiper arms

-

Renew windscreen wiper wheel boxes

-

Electrical systems

-

Engine harness

-

Air conditioning fans harness

-

Chassis harness

-

Main harness

-

MFI harness

-

Radio harness

-

Engine harness connectors

-

Air

conditioning fans harness connectors

-

Multi-port fuel injection harness connectors

-

Main harness connectors

type

A1

27

remove and refit

1

2 5

5

6

9

12

15

16

17

20

21

22

23

24

25

26

28

29

30

33

34

36

REVISED:

OCT

1993

Section

Number

-

Chassis and radio harness connectors

-

Location of relays, timers and control units Defender

-

Location of relays, timers and control units Defender

-

Fuses 42

-

Multi-port fuel injection circuit Defender

-

Multi-port fuel injection circuit Defender

-

Air

conditioning circuit Defender

-

Starting system circuit Defender

-

Starting system circuit Defender

-

Charging and tachometer circuit Defender

-

Charging and tachometer circuit Defender

-

Hazard flasher circuit Defender

-

Hazard flasher circuit Defender

-

Dimming mirror circuit Defender 110

-

Reverse and stop lamp circuit Defender

-

Heated front screen circuit Defender

-

Rear window demist circuit Defender

-

Horn, clock, interior light and auxiliary circuits Defender

-

Horn, clock, interior light and auxiliary circuits Defender

-

Radio system circuit Defender

-

Radio system circuit Defender

-

Lighting circuit Defender 110

-

Lighting circuit Defender

-

Front wash/wipe system circuit Defender

-

Rear wash/wipe system circuit Defender 110

-

Warning lights/check circuit Defender

-

Audible warning system circuit Defender

-

Audible warning system

-

Coolant temperature gauge circuit Defender

-

Coolant temperature gauge circuit Defender

-

Fuel tank level indicator circuit Defender

-

Battery condition indicator circuit Defender

-

Auxiliary feed circuit Defender

-

Centre differential

-

Cigar lighter circuit Defender

-

Split charge and voltage sensitive switch circuit Defender

-

Trailer circuit Defender

locked

110

90

circuit

110

90

110

90

110

90

Defender

90

and 110

110

90

110

90

110

90

and

90

and

and 110

110

90

110

90

and

110

90

110

90

110

Page

38

40

41

45

46

47

48

50

51

52

53

54

55

56

57

58

59

60

61 62 63 64

65

66

67 68 69 70

71

72

73

74

75

REVISED:

OCT

1993

INTRODUCTION

01

This Workshop Manual covers skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Individuals who undertake their own repairs should have some skill and training, components which could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as steering, brakes, or suspension should

Dealer. Repairs to such items should NEVER WARNINGS WARNING: Procedures which must

CAUTION: This calls attention to procedures which must be followed to avoid damage to Components. NOTE: This calls attention to methods which make a REFERENCES

References to the left- or right-hand side the engine and gearbox assembly removed, the water pump end of the engine is referred to as the front. To reduce repetition, operations covered in this manual do not include reference to testing the vehicle after repair.

the vehicle is carried out particularly where safety related items are concerned. DIMENSIONS

The dimensions quoted are following the dimensions, have been converted from the original specification. During the period this Manual. These adjustments thereafter should be maintained at the figures specified

and

CAUTlONS

It is essential that work is inspected and tested after completion and

of

running-in from new, certain adjustments may vary from the specification figures given in

the

Land Rover Defender One Ten vehicles.

be

attempted by untrained individuals.

are given throughout this Manual in the following form:

be

followed precisely to avoid the possibility

job

easier to

in

the manual are made when viewing the vehicle from the rear. With

to

design engineering specification. Alternative unit equivalents, shown in brackets

will

be re-set by the Distributor or Dealer at the After Sales Service, and

in

the Manual.

It

is primarily

be

perform.

designed

and

carried out

of personal

if

necessary a road test of

to

assist

limit repairs to

by

a

Land Rover

injury.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential that only Land Rover parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts an accessories:

in

Safety features embodied territories, legislation prohibits the fitting of parts not setting figures given specified, must be fitted. Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing Service Statement may be invalidated by the fitting All Land Rover parts have the full backing of the Owners Service Statement. Land Rover Distributors and Dealers are obliged

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed

also outlines the other areas of risk which This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be

made

of

your local Fire Officer. Fuel vapor is highly flammable and When fuel evaporates readily ignitable mixture. The vapor distributed throughout a workshop by air current, consequently, even

in

it

the vehicle may be impaired

the Repair Operation Manual must

If

the

efficiency

of

a locking device is impaired during removal

of

to

supply only Land Rover service parts.

must

not be ignored.

in

confined spaces is also very explosive and toxic.

produces

150

times its own volume

is

heavier than air and

if

other than Land Rover parts are fitted. In certain

to

the vehicle manufacturer’s specification. Torque wrench

be

strictly adhered to. Locking devices, where

it

must be renewed.

in

their country of origin. The terms

other than Land Rover parts.

if

fuel

in

vapor, which when diluted with

will

always fall

a

to

the lowest level.

small spillage of fuel

is

to

of

the Owners

be handled safely.

air

becomes

It

can readily be

is

very dangerous.

It

a

REISSUED:

FEB

1993

1

INTRODUCTION

01

Always have a fire extinguisher containing FOAM draining fuel, or when dismantling fuel systems

WARNING:

the battery terminal could ignite fuel vapor in the atmosphere. Always disconnect the vehicle battery BEFORE carrying out work on a fuel system. Whenever fuel is being handled, transferred or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any lead

-

lamps used must be flameproof and kept clear

NO ONE SHOULD BE PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH FUEL WITHOUT FIRST HAVING HAD SPECIALIST TRAINING.

HOT FUEL HANDLING PRECAUTIONS

Before commencing any operation requiring fuel drainage from fuel tanks, the following procedures should

1.

2.

3.

FUEL TRANSFER WARNING: FUEL MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILE IT IS

STANDING OVER A PIT.

It is imperative that the battery is not disconnected during fuel system repairs as arcing at

be

adhered to: Allow sufficient time for the fuel to cool, thus avoiding contact with hot fuels. Vent system by removing the fuel cap

of

tank drainage.

Before disconnecting any part of the fuel system

around components to prevent ingress of foreign matter into the fuel system. Cover the tank apertures after removal to prevent entry

CO

GAS,

or

2

and

in areas where fuel containers are stored.

in

a

well ventilated area replace cap

it

of

dirt and escape of fuel vapors.

POWDER

is vital to remove dirt, dust and debris from

close at

hand

when handling or

until

commencement

The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved transfer tank must

including attention to grounding of tanks.

FUEL TANK REMOVAL

A

fuel vapor label should be attached to the fuel tank upon removal from vehicle.

COMPLETELY DRAINED. FUEL TANK REPAIR

Under no circumstances should a repair to any tank

RECOMMENDED SEALANTS

A

number

These items include:

COMPOUND.

obtaining supplies, contact one

Marston Lubricants Limited Hylo House Prudhoe Cale Wigan, WN2

Tel:

Fax:

Telex:

of

branded products are recommended

Lane,

New Springs Northumberland

1JR

0942 824242

0942

826653

67230

be

used according to the transfer tank manufacturer’s instructions and local regulations,

HYLOMAR GASKET AND JOlNTlNG COMPOUND and HYLOSIL RTV SILICON

They should

ENSURE TANK IS

be

attempted.

in

this manual for use during maintenance and repair work.

be

available locally from garage equipment suppliers.

of

the following companies for advice and the address of the nearest stockist.

Northern Adhesives Limited

NE42 6NP

0661

Tel:

Fax: 0661 35839

32014

If

there is any problem

REISSUED: FEB

1993

INTRODUCTION

POISONOUS AND DANGEROUS SUBSTANCES

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should be kept away from open wounds. These substances among others include

anti

-

freeze, brake fluid, fuel, windscreen washer additives, air conditioning refrigerant, lubricants and various

adhesives.

Engine oils

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminates which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided.

Health protection precautions

1. Avoid prolonged and repeated contact with oil particularly used engine oils.

2. Wear protective clothing, including impervious gloves where practicable.

3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly underpants, with oil.

5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. t aid treatment should be obtained immediately for open cuts and wounds.

barrier creams, applying before each work period, to help the removal of oil from the skin.

h with soap and water to ensure all oil is removed (skin cleaners and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. Do not use petrol, kerosene, Diesel fuel, gas oil, thinners or solvents for washing skin.

9. If skin disorders develop, obtain medical advice immediately.

10. Where possible, degrease components before handling.

11. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields. In addition, an eye wash facility should be provided.

Asbestos

Some components on the vehicle, such as gaskets, brake and clutch linings and friction pads contain asbestos. Inhaling asbestos dust is dangerous

1.

Work out of doors or

2.

Dust found on the vehicle or produced during work should be removed by vacuuming and not blowing.

3.

Asbestos dust waste should be dampened, placed

4.

contains

If

any machining, cutting

to

ensure safe disposal.

in

dampened and only hand

to

health and the following essential precautions must be observed.

a well ventilated area and wear a protective mask.

in

a sealed container and labelled with what

of

drilling is attempted on materials containing asbestos the item should be

tools

or low speed power tools used.

Synthetic rubber

Many “O” ring seals, flexible pipes and other similar items which appear to be natural rubber, are, in fact, made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe and does not present a health hazard. However, if the material is damaged by fire or excessive heating, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious bums on contact with skin. Should the material be in a burnt or over heated condition, handle only with seamless industrial gloves. Decontaminate and dispose of the gloves immediately after use. If skin contact does occur, remove any contaminated clothing immediately and obtain medical assistance without delay. In the meantime, wash the affected area with copious amounts of cold water or limewater for fifteen to sixty minutes.

DISPOSING OF USED

OILS

AND FLUIDS

Environmental protection precaution

It is illegal to pour used oil and other fluids onto the ground, down sewers or drains, or into waterways. Dispose of used oil through authorized waste disposal contractors.

it

REISSUED: FEB

1993

3

INTRODUCTION

01

ACCESSORIES AND CONVERSIONS

Land Rover vehicles are designed and constructed for a variety of uses but no alterations or conversions should be carried out to any vehicle produced by Land Rover which could affect the safety of the vehicle or its passengers.

Land Rover has tested and approved a large number of accessories and conversions, suitable for all models. Before fitting any accessory or commencing any conversion work to any Land Rover vehicle, check that the

accessory or conversion is approved by Land Rover.

WARNING: vehicle. Land Rover may occur

-

approved conversions to Land Rover vehicles.

non SPECIFICATION

Purchasers are advised that the specification details set out in the Manual apply to a range of vehicles and not

to any one. For the specification of a particular vehicle, purchasers should consult their Distributor or Dealer. The Manufacturers reserve the right to vary their specification with or without notice, and at such times and in

such manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer’s policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer nor the Distributor or Dealer, by whom this Manual is supplied, shall in any circumstances be held

liable for any inaccuracy or the consequences thereof.

COPYRIGHT

any form, electronic, mechanical, photocopying, recording or other means without prior written permission of Rover Group Ltd.

DO

as

NOT

FIT

unapproved accessories or conversions, as they could affect the safety of the

will

not accept any liability

a

direct result of fitment of non-approved accessories

for

death, personal injury or damage

to

or

the carrying

property which

out

of

‘4

REISSUED:

FEB

1993

INTRODUCTION

01

Special

The use of approved special tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where special tools are specified, only these tools should be used to avoid the possibility of personal injury or damage to the components. Also the amount of time they

save can be considerable.

Every special tool is designed with the close co and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely.

Special tools bulletins will be issued periodically giving details of new tools as they are introduced.

All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countries where there is no distributor may order direct from V. L. Churchill Limited, P.O. Box 3, Daventry, Northamptonshire, England NN11 4NF.

Service

-

operation of Land Rover Ltd.,

Tools

The tools recommended in this Workshop Manual are listed in a multi from Messrs. V. L. Churchill at the above address under publication number VLC 2561/1/91 or from Land Rover Merchandising Service, P.O. Box 534, Erdington, Birmingham, B24 OQ5.

REISSUED:

FEB

1993

-

language, illustrated catalogue obtainable

5

LOCATION OF VEHICLE IDENTlFlCATlON AND UNIT NUMBERS

VEHICLE IDENTtFlCATlON NUMBER (VIN) The Vehicle Identification Number and the

recommended maximum vehicle weights are

stamped on a plate riveted

to

the top of the brake pedal box in the engine compartment. The number is also stamped on the right of the chassis forward

of

the spring mounting turret.

Always quote this number when writing

-

hand side

to

Land

Rover.

Key to Vehicle Identification Number Plate A

Type approval

B

VIN (minimum Maximum permitted laden weight for vehicle

C

Maximum vehicle and trailer weight

D

E

Maximum road weight - front axle

F

Maximum road weight - rear axle

of

17

digits)

The Vehicle Identification Number identifies the

manufacturer, model range, wheel base, body type, engine, steering, transmission, model name and place of manufacture. The following example shows the coding process.

SAL LD H

M

V

7

=

Land Rover.

=

Land Rover Ninety and One Ten.

=

One Ten inch.

=

4

door

station wagon. A = pick-up hood cab

truck hard

=

V8.

C

=

B

=

2.5

Turbo Diesel.

=

RH

stg. with 5 speed gearbox.

V = Ninety inch.

top.

2.5

Diesel. D

=

2.5

Petrol.

8

=

LH

with 5 speed gearbox.

A

=

Ninety.

B

=

One Ten. E = Ninety,

One Ten 1988 model year.

A

=

Solihull build.

F

=

Assembled locally

from kit.

The

last

six

digits

identify

build sequence

number.

The

V8

engine serial number

is

stamped on a cast pad on the cylinder block between numbers cylinders.

stg.

3

and

5

REISSUED:

FEB

1993

7

MAIN GEARBOX LT77 FRONT AXLE

Stamped on a pad on the right-hand side

gearbox immediately below the

TRANSFER GEARBOX

LT230T

oil

filler level

of

plug.

the

Stamped on top

REAR AXLE

Stamped

on

top

illustrated)

on

of

left-hand axle tube for

.

of

the left-hand axle tube.

rear

of

left-hand axle tube on

90

models

110,

(110

and

axle

8

REISSUED:

FEB

1993

GENERAL SPECIFICATION DATA

ENGINE

Type Number

Bore Stroke

Capacity Valve operation

Compression ratio Maximum power

Crankshaft

Main journal diameter Minimum regrind diameter Crankpin journal diameter Minimum regrind diameter Crankshaft end thrust/(end float)

Main bearings

Number and type Material

Diametrical clearance Undersize bearing

3.9

V8

.....................................................................................

of

cylinders

.............................................................

.....................................................................................

...................................................................................

...............................................................................

....................................................................

................................................................

...................................................................

..........................................................

...................................................

....................................................

...................................................

.........................................

.................................................................

................................................................................

..........................................................

shells

......................................................

V8 Eight,

two

banks

of

four

94.00 mm

71.12 mm 3950 cc

Overhead by push-rod

9.35:1

134kW

58.409-58.422 mm

57.393-57.406 mm

50.800-50.812

49.784-49.797 mm Taken on thrust washers

0.10

5,

Lead-indium

0.010-0.048 mm

0.254

at

4750 rev/min

mm

-

0.20 mm

Vandervell shells

mm,

0.508

mm

of

centre main bearing

Connecting rods

Type

.....................................................................................

Length between centres

Big-end bearings

Type and material

Diametrical clearance

-

float crankpin

End Undersize bearing shells

Piston pins

Length Diameter Fit Clearance

..................................................................................

..............................................................................

-

in connecting rod

in

piston

.......................................................

.................................................................

..........................................................

................................................................

......................................................

............................................................

.......................................................

Horizontally split big-end, plain small-end

143.81-143.71 mm

Vandervell

0.015-0.055 mm

0.15-0.36mm

0.254 mm,

72.67-72.79 mm

22.215-22.220 mm Press

0.002-0.007 mm

fit

VP

lead-indium

0.508

mm

REISSUED:

FEB

1993

1

GENERAL SPECIFICATION DATA

Pistons

Clearance in bore, measured at bottom of skirt at right angles to piston pin

Piston rings

......................................

0.018-0.041 mm

Number of compression rings

Number No 1 compression ring No 2 compression ring

Width of compression rings Compression ring gap

Oil control ring type

Oil

Oil control ring rail gap

Camshaft

Location

Bearings Number of bearings Drive

Tappets

Valves

Length: Seat angle:

Head diameter: Stem diameter: Stem

Valve Valve spring length fitted

of

control rings

.........................................................

..........................................................

..............................................................

control ring width

............................................................

.........................................................

...............................................................................

.............................................................

.....................................................................................

...........................................................................

to

guide clearance:

lift

(Inlet

and Exhaust)

..............................................

........................................................

..................................................

...................................

Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust

.............................

...................................

.............................

...................................

.............................

...................................

.............................

...................................

.............................

..............;.................................

......................................................

2

1

Molybdenum barrel faced

Tapered and marked ‘T' or ‘TOP'

1.478-1.49 mm

0.40-0.65 mm Hepworth and Grandage

3.0

mm

0.38-1.40 mm

Central Non serviceable

5

Chain 9.52 mm pitch x 54 pitches.

Hydraulic-self-adjusting

116.59-117.35 mm

116.59-117.35 mm 45°

to

45 1/2°

45°

to 45 112°

39.75-40.00 mm

34.226-34.480 mm

8.664-8.679 mm

8.651-8.666 mm

0.025-0.066 mm

0.038-0.078 mm

9.49 mm

40.4

mm at pressure

of

29.5

kg

Lubrication

System type............................................................................ Wet sump, pressure fed

Oil pump

Oil pressure Oil filter

Oil filter-external

2

type

........................................................................

-

internal .................................................................... Wire screen, pump intake filter

...................................................................

REISSUED:

Gear

2.11 to 2.81 kg/cm² (30 to with engine warm

Full flow, self-contained cartridge

FEB

1993

40

p.s.i) at 2400 rev/min

in

TRANSMISSION

Main gearbox

-

Type

Main gearbox ratios

Transfer gearbox

Type

Overall ratio

Manual

.............................................................

.....................................................................................

..........................................................................

GENERAL

LT77

5-speed helical constant mesh, with synchromesh on all forward gears Fifth (Cruising gear) Fourth 1.000:1

Third 1.436:1

Second 2.180:1 First Reverse 3.718:1

LT230T. Two-speed reduction on main gearbox output. Front and rear drive permanently engaged via a lockable differential.

Fifth (Cruising gear) 3.9663:1 9.3401:1 Fourth 4.9893:1 11.7471:1 Third 7.1656:1 16.8712:1 Second First 18.2094:1 Reverse 18.9497:1 44.9233:1

SPECIFICATION DATA

0.795:1

3.650:1

In

high

transfer transfer

10.8786:1

In low

25.6134:1

42.3734:1

Rear Axle - One Ten only

Type

Ratio ....................................................................................

Track .................................................................................... 1485,90 mm

Rear Axle - Ninety only

Type

Ratio

Track

Front

Type Ratio Track

PROPELLER

Type: Front and rear

SUSPENSION

Type

Front .................................................................................. Transverse location of axle by Panhard rod. and fore

Rear ..................................................................................... Fore and aft movement inhibited by two trailing links

.....................................................................................

....................................................................................

Axle

.............................................................................................................

..................................................

....................................................................................

SHAFTS

.......................................................

.....................................................................................

Salisbury 8HA

3.538:1

Land Rover spiral bevel

3.538:1

1485,90 mm

Land Rover spiral bevel

3.538:1

1485,90 mm

Single Hookes universal needle roller joints.

Coil springs controlled by telescopic dampers and rear

and aft location by two radius arms Lateral location of axle by a centrally positioned 'A'

bracket bolted at the apex to a ball joint mounting. Defender 110 has a levelling unit is positioned between the ball joint and upper cross member

front

REVISED:

OCT

1993

3

GENERAL SPECIFICATION DATA

BRAKES

System

Foot

Front

Rear

Rear drum brakes

.................................................................................

brake

Type

..........................................................................

Disc Diameter.......................................................

of

Number Total lining area Lining material

disc Type Disc diameter Number

Lining material .................................................. Don 230 (Asbestos) or Ferodo 3440

Type Drum diameter Total lining area Brake drum width Lining material

pistons per wheel

......................................

..................................................................

brakes

.....................................................................

................................................................

of

pistons per wheel

..............................................................................

..............................................................

............................................................

..........................................................

..............................................................

...................................

........................................

Direct acting servo assisted dual braking system Girting tandem master cylinder and G valve

Lockheed Disc

300

mm

4

(Asbestos) or Ferodo 3440 (Asbestos free)

Lockheed

290

mm

D

I

S

C

2

Girting single cylinder drum brake

280

mm

493

cm²

63.9

mm

Ferodo

2629

with

Handbrake Type Drum diameter Lining material

...........................................................................

.....................................................................

......................................................................

Transmission drum brake cable operated

254

Don

STEERING

Power

Make/type Ratio Steering wheel turns, lock-to-lock

Steering

Make/type

Operating pressure - straight ahead position - at idle

Full lock (left Full lock (left

Steering geometry Steering

Toe Toe

Camber

Castor angle ................................................................... 3°

Swivel pin inclination static Steering damper Steering column

steering

box

............................................................................

.............................................................:.......................

...................................

pump

............................................................................

..........

or

right) at idle

or right)

wheel

diameter

-

out measurement

-

out included angle

angle

..................................................................

type

1000

.............................,...................

rev/min

......................................

......................................................

........................................................

.....................................................

...........................................

...............................................

Adwest Varamatic - worm and roller box Variable: straight ahead

3.75

Hoboum-Eaton series 200

7 kgf/cm² (100 p.s.i.) maximum

28

70-77 kgf/cm² (1000-1100 p.s.i.)

420mm 0

0° to 0° 16' 0° Check with vehicle in static

7°

Double acting

housing

Collapsible coupling

mm

269

kgf/cm²

to

2.0

mm

(400

p.s.i.) minimum

fitted

between drag link and pinion

19.3:1

on lock

unladen condition. that is. vehicle with water. oil and five gallons of fuel

Rock the vehicle up and down at the front to allow it to take up a static position

17.2:1

4

REVISED:

OCT

1993

GENERAL SPECIFICATlON

DATA

ELECTRICAL

System

Battery

Type:

Alternator

Type

Maximum

Rotor Stator New brush length Renew brush at Brush spring pressure Regulator controlled voltage

Starter motor

Type Brush spring tension Brush minimum length

............................................................................................

Lucas Chloride Lucas - cold climate 13 plate Chloride

.....................................................................................

-

winding resistance

-

winding resistance per phase

.....................................................................................

EQUIPMENT

-

standard 9 plate

-

standard 9 plate

-

cold climate 13 plate

D.C.

output at 6000 rev/min

...............................................

...........................................

....................................

................................

...................................................

..................................

.................................................................

....................................................................

..........................................................

................................................

............................................................

.........................................................

12 volt, negative ground

B.B.M.S. No.371 B.B.M.S. B.B.M.S. No.389 Designation B.B.M.S. No.3693

Magnetti Marelli A127-85

85

2.6 ohms at 2O°C ± 5%

0.092 ohms at 20°C ± 5%

20

10 mm

1.3 - 2.7 N

13.6 - 14.4 volts measured across battery

Magnetti Marelli M78R pre-engaged

1020 gms

9,5 mm

No.2911

amps

mm

Designation 90/84/90

15/120/92

Distributor & MFI system

Wiper

Type Armature end-float Minimum brush length

Fuses

Type

motor

.....................................................................................

...............................................................

.....................................................................................

..................................................

..........................................................

See

‘ENGINE TUNING

Lucas

14W uprated two

0,1 - 0,20 mm

4,8 mm

Cartridge fuses, located

panel, which protect the electrical components.

A complete list of circuits protected is given in

Electrical Section.

A second fuse box located in the engine compartment

next to the brake servo contains fuses to protect the vehicle harness. For fuse values refer to the Electrical Section.

DATA'

-

speed

in

a

box below the facia

REVISED:

OCT

1993

5

GENERAL

Coil

Make/type Distributor

Make/type

Firing angles .................................................................

Application Pick

(Pick-up Iimb/reluctor tooth) Pick-up winding resistance

Horns Make/type

........................................................

............................................................................

...........................................................................

up air gap adjustment

............................................................................

SPECIFICATION

DATA

.................................................

..................................................

Bosch

0221 122 392

Lucas

35

DLM8

0°-45°-90° (every 45°) ± 1°

12V

Negative ground

0.20 mm to 2k

to

Klamix

0.35

5k ohms

(Mixo)

mm

TR99

Ignition

Make/type

Spark plugs Make/type

REPLACEMENT BULBS AND UNITS

Headlamps

Front side lamps Side marker lamps Stop/tail lamps High mounted stop light Flasher lamps

Number plate lamp

Reverse lamp

Interior lamp Warning lights Instrument illumination

Hazard switch warning light Heated rear Screen switch illumination Heated front screen switch Heated front Screen warning light Cigar light illumination

module

............................................................................

...........................................................................

..................................................................

...............................................................

.....................................................................

.......................................................

......................................................................

...............................................................

.......................................................................

.........................................................................

......................................................................

.........................................................

.................................................

illumination

........................................

..........................................................

................................

...............................

Lucas 9EM amplifier module, distributor mounted

Champion RN9YC

60/55

W

halogen sealed beam

12V 5W 12V

3W

12V 21/5W 12V/5W 12V

21W

12V

4W

12V

21W

12V

21

W

12V

1.2W

12V 2W 12V 1.2W 12V

12V 1.2W

12V

12V 1.2W

1.2W

(red)

(green)

(amber)

6

RE-ISSUED: FEB

1993

GENERAL

SPECIFICATION DATA

VEHICLE DIMENSIONS

Overall length Overall width

...............................................................

........................................................................

110

..................................................................

Wheelbase Track: front and rear Ground clearance: under differential Rear opening height (interior)

VEHICLE

Overall length

Overall width Overall height Wheelbase Track: front and rear Ground clearance: under differential Tailgate aperture width Tailgate height Interior width Width between wheelboxes

VEHICLE WEIGHTS AND PAYLOAD

..........................................................................

............................................................

....................................

..............................................

DIMENSIONS

90

.......................................................................

........................................................................

.......................................................................

...........................................................................

............................................................

....................................

........................................................

.....................................................................

........................................................................

.................................................

1790mm 2035mm

2794mm

1485,90mm

215mm

1205mm

4072mm

1790mm

2035mm

2360mm

1485,90mm 229mm 864mm

1300mm

1450mm 925mm

When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken kerb weight and the distribution maximum values. It

that neither maximum axle loads nor

NOTE:

is

the customer's responsibility

CURB WEIGHT

of

the payload to ensure that axle loadings do not exceed the permitted

to

limit the vehicle's payload in an appropriate manner such

Gross

Vehicle Weight are exceeded.

equals the minimum unladen vehicle weight plus full fuel tank.

of

the

vehicle

GROSS

payload equipment and towing attachment load (where applicable)

GROSS

loadings which allow for the fitting respective maximums be exceeded.

VEHICLE WEIGHT

VEHICLE WEIGHT CONDITION

MUST BE

equals the maximum all up weight, with the driver, passengers.

of

optional equipment. The loading of

AVOIDED,

REVISED: OCT

-

the maximum axle weights shown

as the overall maximum vehicle weight

1993

both

are

individual

axles

up

to

would

axle

their

then

7

GENERAL SPECIFICATION DATA

WHEELS DEFENDER

AND

90

TIRES

Wheels

7.0

X

7J

16

X

16 X 33

Steel

Alloy

Tires

BF

Type and size

DEFENDER

110

Goodrich LJ265/R16 Mud Terrain

Wheels

x

Steel 139,70mm

406,40mm

Tires Type and size 750X 12,8m (tubed)

TIRE

PRESSURES

WARNING: Tire pressures must

If

at running temperature.

the vehicle has been parked

be

checked with the tires cold, as the pressure is about 0,21 bar higher

In

the sun

or

USE

RADIAL PLY

high ambient temperatures, Do not

reduce the tire pressures, move the vehicle into the shade and wait for the tires

the pressures.

Radial

to

cool before checking

Ply

TIRES

ONLY

General Notes

Emergency soft pressures should

Max

speed

40

Towing When vehicle is

applicable

WARNING:

Do not

they are designed

proper operation

of

size recommended

doubt,

8

consult

Land

only

be

used

in

extreme conditions where extra flotation

km/h

(25

mph). Return pressures

used

for

replace

for

the road wheels with any type other than genuine Land Rover wheels,

multi-purpose on and

towing

off

to

normal immediately firm ground is regained.

the reduced rear tire pressures for extra ride comfort are not

road use and have very important relationships with the

the suspension system and vehicle handling. Replacement tires should

in

this manual and all be the same make, ply rating and tread pattern.

Rover

Service department

REVISED:

for

advice.

OCT

1993

is

required

be

If

in

of

as

the

any

ENGINE

TUNING

DATA

ENGINE

Type Firing order Cylinder Numbers

Left bank Right bank

No

Timing marks Spark plugs

Gap

Coil

Make/type

Compression ratio Fuel injection system

Valve Timing Inlet Exhaust

Opens Closes Duration

Valve peak 104° ATDC 114° BTDC

3.9

V8

.....................................................................................

.........................................................................

..............................................................................

............................................................................

1

Cylinder location

.......................................................

......................................................................

......................................................................................

............................................................................

.............................................................

........................................................

..................................................................................

...............................................................................

...........................................................................

3.9 Litre V8 1-8-4-3-6-5-7-2

1-3-5-7 2-4-6-8

Pulley end

On crankshaft vibration damper

0.84-0.96mm

Bosch 0-221-122-392, (ETC 6574)

9.35:1

Lucas 14 CUX Hot-wire air

electronically controlled

32° BTDC

73° ABDC

285° 285°

of

left bank

flow

sensor system

70° BBDC

35° ATDC

Idle speed - controlled by Base idle speed Ignition Timing - dynamic at idle speed,

vacuum disconnected Exhaust gas

CO content at idle

..................................................................

................................................................

MFI

system

.............................

.......................................................

700 ± 25 rev/min See setting procedure - 525 ± 25 rev/min.

5° BTDC ±

0%

to

1

°

0.05% max.

REISSUED:

FEB

1993

1

ENGINE Nm

Alternator mounting bracket to cylinder Alternator

Alternator to adjusting link Chainwheel to camshaft

Connecting rod bolt Cylinder head:

Outer row Centre row

Inner row Distributor clamp nut

Exhaust manifold Fan Flywheel

Inlet manifold

Lifting eye Main bearing cap bolts

Main bearing cap rear bolts Manifold gasket clamp bolt Oil pump cover

Oil plug

Oil

relief valve cap

Oil sump drain plug

Oil

sump

Oil

sump rear

Rocker cover to cylinder head Rocker shaft bracket

Spark plug Starter motor attachment

Damper Timing cover Viscous unit Water pump pulley to water pump hub Water pump timing cover

to

mounting bracket

.............................................

....................................................

.......................................................

..............................................................

.............................................................................

...........................................................................

..............................................................................

............................................................

to

cylinder heads

to

viscous unit

to

crankshaft

to

...............................................................

.........................................................

to

cylinder heads

...........................................

................................................

.........................................................

.................................................

..................................................

to

timing cover

............................................

.................................................................................

................................................................

..............................................................

to

cylinder block

to

cylinder block

....................................................

.............................................

to

cylinder head

............................................................................

.....................................................

to

crankshaft

to

...........................................................

cylinder

water pump hub

block

...........................................

to

cylinder block

head

......................

.....................................

..................................

..............................................

................................

..........................

40

24 24

58

51

58 92

92 21

21

30 78

51

24 72

92

17

13

28

40

45

10 18

7 37

15

44

271

27

45

10

27

TORQUE

WRENCH

SETTINGS

FUEL LINES

Connections at straight connector

Pipe connections at filter

Hose clips Connections at vapour separator

Connections at Tee-piece

CLUTCH

Clutch cover bolts

Slave cylinder bolts

............................................................................

......................................................

....................................................

................................................................

..............................................................

.......................................

.........................................

16 16

2

16 16

27 27

REISSUED:

FEB

1993

1

TORQUE WRENCH SETTINGS

MAIN GEARBOX (FIVE-SPEED)

Oil pump body to extension case

Clip

to

clutch release lever Attachment plate Attachment plate Extension case Pivot plate Remote selector housing to extension case Gear lever housing

Guide

clutch release sleeve Slave cylinder Front cover

5th support bracket Plunger housing

Blanking plug extension case Gear lever retainer Yoke

to

selector shaft Fixing gear lever assembly nut Reverse pin

Clutch housing

Plug - detent spring

Oil drain plug Oil filter plug Plug

oil

filler - remote housing

Breather Oil level plug Blanking plug - reverse switch hole Fifth gear layshaft nut

...............................................................................

to

gearcase

to

remote housing

to

gearcase

............................................................................

to

clutch housing

to

gearcase

..............................................................

to

remote housing

...............................................................

to

centre plate nut

to

gearbox bolt

..............................................................

........................................................................

.........................................................................

........................................................................

......................................

remote housing

.......................................................

..........................................................

LT77S

.........................................

..................................

....................................

.................................................

.................................

.................................................

...........................................

.....................................

..............................................

............................................

..............................................

.....................................

........................

Nm

9

25 25 25 25 25

25

25 25 25

9 9

25

44

25 72

25

51

72

30

9

30

24 217

2

REISSUED:

FEB

c

1993

TORQUE

WRENCH

SETTINGS

TRANSFER

Fixings securing mounting brackets Pinch bolt operating arm Gate plate Bearing housing Speedometer cable retainer

Speedometer housing

Locating plate to gear change

Bottom

Front output housing to transfer Front output housing Cross shaft housing to front output housing Gear change Gear change Cross shaft to high/low lever

Pivot shaft to link arm Connecting rod Anti-rotation plate intermediate shaft Front

output

Pivot

bracket

Finger housing Mainshaft bearing housing to transfer case

Brake drum to coupling flange

Gearbox to transfer case End cover bearing housing to transfer case Speedometer housing Selector finger Selector fork high/low

Transmission

Gearbox

Transfer case assembly Oil drain plug

Detent plug

Differential casings Front and rear out flange Differential case rear Oil filler and level plug transfer

Transfer breather

Inner shaft stake nut

GEARBOX

LT230T Nm

to

gearbox

......................................................

to

grommet plate

to

transfer case

................................................

.........................................

.................................................

..........................................................

..............................................

cover to transfer

.......................................................

...........................................

to

transfer

...........................................

........................................................................

................................................

...........................................................

.....................................................................

...................................

housing cover

to

extension housing

to

front output housing

..................................................

......................................

................................

.............................................

.....................................................

to

cross shaft (high/low)

brake

to

transfer case

transfer

to

shaft

to

speedometer housing

.........................................

...............................

...................................................

.....................................................

.......................................................

........................................................................

...........................................................................

...............................................................

.....................................................

............................................................

.............................................

.................................................................

............................................................

...................

........................

.........................

........................

................

90

9

See note

6

25

25 25

25

45

25

72

45

See

note

30

Plug

to

be coated with Hylomar and peened Screw

plug fully in (spring solid) then turn two complete turns

.

back

60

162

.

72

30 9

135

N0TE:

sufficient torque to wind them torque must not exceed the maximum figure quoted

for the associated nut on final assembly

FRONT AXLE

Hub driving member Stub axle Upper swivel pin to swivel pin housing Lower swivel pin

Oil

Swivel

Pinion housing Crown wheel Differential bearing cap to pinion housing Universal Joint flange to propeller shaft

Mudshield Bevel pinion nut

Studs

to

be assembled

to

hub

..................................................

to

swivel pin housing

to

swivel pin housing........................

seal retainer

bearing housing to axle case

to

swivel pin housing

to

axle case

to

differential case

swivel pin housing

.................................................

...................................................................

into

casings with

fully

home, but this

.

............................................

................................

.............................

....................................

..........................................

............................

...............................

..........................................

REISSUED:

65

25

9

72

41

58

90

47

9

129

FEB

1993

3

Land Rover Defender 90 1993 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

REPAIRS AND REPLACEMENTS

FUEL HANDLING PRECAUTIONS

HOT FUEL HANDLING PRECAUTIONS

FUEL TANK REMOVAL

RECOMMENDED SEALANTS

POISONOUS AND DANGEROUS SUBSTANCES

Engine oils

Health protection precautions

Asbestos

Synthetic rubber

Environmental protection precaution

ACCESSORIES AND CONVERSIONS

LOCATION OF VEHICLE IDENTlFlCATlON AND UNIT NUMBERS

MAIN GEARBOX LT77 FRONT AXLE

REAR AXLE

Crankshaft

Main bearings

Connecting rods

Big-end bearings

Piston pins

Pistons

Piston rings

Camshaft

Tappets

Valves

Lubrication

TRANSMISSION

Transfer gearbox

Rear Axle - One Ten only

Rear Axle - Ninety only

SUSPENSION

BRAKES

STEERING

Battery

Alternator

Starter motor

Distributor & MFI system

Fuses

Coil

REPLACEMENT BULBS AND UNITS

VEHICLE WEIGHTS AND PAYLOAD

ENGINE Nm

FUEL LINES

CLUTCH

FRONT AXLE