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

TORQUE

WRENCH

SETTINGS

REAR AXLE AND FINAL DRIVE

Crown wheel to differential case

Rear cover to axle case Ball joint mounting bracket to axle case Universal Joint flange Drum to hub

Rear brake assembly and stub axle rear to axle

Hub driving member to hub

PROPELLER SHAFTS

Coupling flange bolts

REAR SUSPENSION

Bottom link to chassis nut

Bottom link to mounting rubber Top link bracket to chassis Bump stop rubber bracket nuts Shock absorber bracket to chassis

Shock absorber upper attachment to bracket

Anti

roll bar bush to chassis nuts Upper link ball joint to axle castle nut Anti roll bar ball joint castle nut

Shock absorber lower attachment nuts

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

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

to

propeller shaft

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Nm

160

24 133 47 18

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

65 65

46

176

64

47

32

64

82 24

40 75

176

STEERING AND FRONT SUSPENSION

Tie bar to mounting arm nut

Mounting arm to chassis nuts

Tie bar to steering box nuts

Panhard rod to mounting arm nut Panhard rod Panhard rod mounting bracket to chassis bolts Drop arm to drag link castle nut

Steering damper to drag link nut

Drop arm to steering box nut Radius arm to axle nuts Steering box to chassis nuts

Radius arms to chassis nuts

Track rod clamp bolt nuts

Drag link clamp bolt nuts

Steering wheel retaining nut

Road wheel nuts Ball joint nuts

Collapsible coupling nuts

to

anchor bracket nut

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

81

81 176

81 88 88

123

81

50

176

176 176

14 14

30

108

41

25

4

REISSUED:

FEB

1993

TORQUE

WRENCH

SETTINGS

POWER ASSISTED STEERING

Mounting bracket to front cover

Mounting bracket Mounting plate

Pulley to P A S pump P.A.S pump P.A.S box

P.A.S box 14 mm thread P.A.S pump union

P.A.S pump Jubilee clips

BRAKES

Brake disc to hub Brake caliper to swivel housing

Brake pipe connections

Servo. primary port Servo. secondary port Jump hose Wheel cylinders to back plate 'G'

valve

'G'

valve

Master cylinder Servo to bulkhead nuts

16

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

to

cylinder block

to

mounting bracket

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

to

mounting bracket

mm thread

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

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

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

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

-

female

bracket

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

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

to

servo nuts

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

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

to:

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

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

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

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

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

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

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

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

Nm

25 25

25

9

25

20

15

20

3

72

100

13 13 15

11

10

13 14

14

ELECTRICAL EQUIPMENT

Alternator:

Shaft nut Through bolts

Rectifier bolts

Starter motor to engine bolts Starter motor:

Through bolts Solenoid fixing stud nut

Solenoid upper terminal nut

Reverse light switch

Lucas

Pick up bearing plate support pillars Pick up barrel nuts

AIR

Adaptor plate Compressor mounting bracket

Mounting plates

Compressor to mounting bracket Adjusting link to mounting bracket & compressor Belt damper

Pulley

35

CONDITIONING

to

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

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

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

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

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

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

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

DM8 Electronic ignition distributor

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

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

to

front cover

to

compressor

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

to

adaptor plate

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

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

to

front cover plate

Torsional Vibration damper

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

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

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

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

60

5 3,5

44

10,8

6

4

24

1,2

45

45 25

45

36

25

REISSUED: FEB

1993

5

GENERAL FITTING INSTRUCTIONS

PRECAUTIONS AGAINST DAMAGE PREPARATION

1.

Always fit covers

commencing work in engine compartment. surrounding areas as thoroughly as possible.

2.

Cover seats and carpets, wear clean overalls and wash hands or wear gloves before component removal, using greaseproof paper working inside car.

3.

Avoid spilling hydraulic fluid or battery acid on paint work. Wash this occurs. Use Polythene sheets in boot protect carpets.

4.

Always use a recommended Service a satisfactory equivalent, where specified.

5. Protect replacing nuts or fitting plastic caps. in a suitable container; use a separate

temporarily

SAFETY PRECAUTIONS - (See

-

Poisonous Substances)

1.

Whenever possible use a ramp or pit when agent; check that agent is' suitable for all working beneath vehicle, in preference

jacking. Chock wheels as well as applying

hand brake. labels, containers and locking wire before

2.

Never rely on a jack alone

Use axle stands or blocks carefully placed at

jacking points

3.

Ensure that a suitable form

is conveniently located.

4.

Check that any lifting equipment used has dismantling components, particularly when adequate capacity and is

5.

Inspect power leads of any mains electrical worked on. equipment for damage and check that properly earthed.

6.

Disconnect earth (grounded) terminal of vehicle battery. and fluid passages with an air line. Ensure

7.

Do not disconnect any pipes in air that any O-rings used for sealing are correctly conditioning refrigeration system, if fitted, replaced or renewed, unless trained and instructed refrigerant is used which can cause blindness replaced as dismantled. Whenever possible if

allowed to contact eyes. use marking ink, which avoids possibilities

8.

Ensure that adequate ventilation when volatile degreasing agents are being punch

to

used.

WARNING: Fume extraction equipment must

be

in operation when trachloride, methylene chloride, chloroform or perchlorethylene are purposes

Do not apply heat in an attempt to free stiff rebuild.

9.

nuts protective coatings, there is a risk of damage to electronic equipment and brake lines from that its correct replacement stray heat. obtained.

10.

Do around or

11.

Wear protective overalls and use barrier creams when necessary.

.

or

fittings; as well as causing damage to

not

leave

on

work area.

to

protect wings before

off

with water immediately

exposed screw threads by

also SECTION

to

support vehicle.

provide rigid location.

of

fire extinguisher

fully

serviceable. brake, fuel or hydraulic system parts are being

to

tools,

used

equipment, spilt oil etc.,

for cleaning

1.

Before removing a component, clean

2.

Blank and masking tape.

3.

Immediately seal fuel, oil or hydraulic lines

if

to

Tool,

or component removal, with tapered hardwood

01

to

when separated, using plastic caps or plugs,

to

4.

Close open ends of oilways, exposed by plugs or readily visible plastic plugs.

5.

Immediately a component is removed, place container for each component and its

associated parts.

6.

Before dismantling a component, clean thoroughly with a recommended cleaning

materials of component.

7.

Clean bench and provide marking materials, dismantling a component.

off

prevent

any openings exposed by

loss

of fluid and entry

DISMANTLING

1.

Observe scrupulous cleanliness when

A

particle

it

is fragment could cause a dangerous

malfunction

2.

Blow

do

so.

A

is

provided distortion or initiation of cracks, liable

3.

Mark mating parts to ensure that they are

4.

Wire together mating parts where necessary to

prevent accidental interchange (e.g. roller

bearing components).

5.

Wire

renewed, and to parts requiring further inspection before being passed for reassembly; place these parts in separate containers from those containing parts for

6.

Do not discard a part due for renewal until

after comparing it with a new part, to ensure

if

trapped

out

ail tapped holes, crevices, oilways

or

scriber are used.

labels

on to all parts which are to be

of

dirt or a cloth

in

these systems.

if

disturbed.

of

it

dirt.

has

and

if

centre

its

it

of

been

REISSUED:

FEB

1993

1

GENERAL

FlTTlNG

INSTRUCTIONS

INSPECTION - GENERAL

1.

Never inspect a component for wear or dimensional check unless clean; a slight smear of grease can conceal an incipient failure.

2.

When a component is to be checked dimensionally against figures quoted for it, use correct equipment (surface plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift checking equipment can be dangerous.

3.

Reject a component outside limits quoted, or apparent. A part may, however, be refitted

its critical dimesnion is exactly limit size, and

is otherwise satisfactory.

4. Use plasti-guage 12 bearing surface clearances; directions for its use, and a scale giving bearing clearances in

0,0025 mm steps are provided with it. bearings (e.g. taper roller bearings)

BALL

AND

ROLLER BEARINGS

it

is absolutely to inner ring

if

its dimensions are

if

Type PG-1

for checking

damage is

if

it

could be established that damage was

confined to

9.

When fitting bearing to shaft, apply force only

it

only.

of

bearing, and only to outer ring

when fitting into housing.

10.

In the case of grease-lubricated bearings (e.g.

hub bearings) fill space between bearing and outer seal with recommended grade of grease before fitting seal.

11.

Always mark components of separable dismantling, to ensure Correct reassembly.

Never

fit

new rollers in a used cup.

in

NEVER

WITHOUT

SERVICABLE CONDITION

REPLACE

FIRST

1.

Remove all traces of lubricant from bearing replace a seal exactly when

under inspection by washing

A

BALL

ENSURING THAT

OR

ROLLER

IS

in

suitable degreaser; maintain absolute cleanliness throughout operations.

2.

Inspect visually for markings of any form on rolling elements, raceways, outer surface of dust excluder seals

outer

rings or inner surface of inner rings. grease duplex seals in cavity between sealing

Reject any bearings found to be marked, lips. since any marking in these areas indicates

onset of wear. correctly

.

Holding inner race between finger and thumb of one hand, spin outer race

and

revolves absolutely smoothly, Repeat, holding sleeve when possible to protect sealing lip outer race and spinning inner race.

4.

Rotate outer ring gently with a reciprocating splines, motion, while holding inner ring; feel for any plastic tube check or obstruction to rotation, and reject damage to sealing lip.

bearing if action is

5. Lubricate bearing generously

appropriate

6. Inspect shaft and bearing housing for

to

not

perfectly smooth.

installation.

with

discolouration or other marking suggesting

i

that movement has taken place between

bearing and seatings. (This is particularly to

be

expected if related markings were found in

operation

2.)

If markings are found, use

'Loctite' in installation of replacement bearing.

7.

Ensure that shaft and housing are clean and

free from burrs before fitting bearing.

8.

If one bearing of a pair shows an imperfection

it

is

generally advisable to renew both bearings: an exception could be made faulty bearing had covered a low mileage, and

BEARING

IN

A

FULLY

petrol

or

check that

lubricant

if

O

I

L

SEALS

1.

Always fit new oil seals when rebuilding an assembly. It is not physically possible to

a down.

2.

Carefully examine seal before fitting to ensure that it is clean and undamaged.

3.

Smear sealing lips with clean grease; pack

4.

Ensure that seal spring, if provided,

5.

Place

it

and slide into position on shaft, using fitting

from damage by sharp corners, threads or

the

it

has bedded

with

grease, and heavily

is

fitted.

lip of seal towards fluid to be sealed

If

fitting sleeve is not available, use

or

adhesive tape to prevent

2

REISSUED: FEB

1993

GENERAL FITTING INSTRUCTIONS

6.

Grease outside diameter of seal, place square

FLEXIBLE

HYDRAULIC

PIPES,

HOSES

to housing recess and press into position,

using great care and

if

possible a 'bell piece'

Before removing any brake

or

power steering

1.

to ensure that seal is not tilted. (In some hose, clean end fittings and area surrounding cases housing before fitting to shaft.) Never let

weight of unsupported shaft rest in seal.

it

may be preferable to fit seal to them as thoroughly as possible.

2. Obtain

appropriate blanking caps before

detaching hose end fittings,

be immediately covered

3.

Clean hose externally and blow through

to

so

that ports can

exclude dirt.

airline, Examine carefully for cracks, separation of plies, security of end fittings and external damage.

Reject

any hose found

faulty.

4.

When refitting hose, ensure that no unnecessary bends are introduced, and that hose is not twisted before

or

during tightening

of union nuts.

5.

Containers

for

hydraulic fluid must be kept

absolutely clean.

6.

Do

not store hydraulic fluid in an unsealed

7.

If

correct service tool is not available, use a contaminated

suitable drift approximately

container. condition would be dangerous

lowering

7.

Do

0,4

mm smaller container which has previously contained

It

will

absorb water, and fluid in this

to

use due to a

of

its boiling point.

not allow hydraulic fluid

with

mineral oil, or use a

than outside diameter of seal. Use a hammer mineral oil. VERY GENTLY on drift suitable.

8.

Press or drift seal

is

housing

shouldered,

in

housing where no shoulder is provided. plug

if

a press is not

to

depth of housing

or

flush with face of

if

8.

Do

not re-use fluid bled from system.

9.

Always use clean brake fluid to clean hydraulic components.

10.

Fit a blanking cap to a hydraulic union and a

to

its socket after removal

to

Ensure that the seal does not enter the ingress of dirt.

housing

in

a tilted position.

11.

Absolute cleanliness must be observed hydraulic components at all times.

NOTE: Most cases of failure or leakage of oil seals are due to careless fitting, and resulting damage to both seals and sealing surfaces. Care in fitting is essential results are to

be

obtained.

if

good

12.

After any work on hydraulic systems, inspect carefully for leaks underneath the vehicle while a second operator applies maximum pressure

to

the brakes (engine running) and

operates the steering.

with

to

be

prevent

with

JOINTS

1.

Always use correct gaskets where they are

2. recommended. Otherwise fit joints dry.

3.

When jointing compound is used, apply in a thin uniform film to metal surfaces; take great care to prevent

4.

5.

6.

AND

JOINT

FACES

specified. Use jointing compound only when

it

from entering oilways, pipes or blind tapped holes. Remove all traces of old jointing materials prior to reassembly.

Do

not use a tool which could damage joint faces. Inspect joint faces for scratches or burrs and

or

remove with a fine file allow swarf

or

dirt to enter tapped holes or

oil stone; do not

enclosed parts.

Blow out any pipes, channels

compressed air, renewing any O

or

crevices with

-

rings or

seals displaced by air blast.

REISSUED: FEB

1993

3

GENERAL

FITTING

INSTRUCTIONS

METRIC

BOLT

1.

An

IS0 and larger than 6 mm identified by either of the symbols IS0 M or embossed or indented on top of the head.

2.

In addition manufacture, the head is also marked with symbols

8.8, gives the minimum tensile strength of the bolt Metric threads and metric sizes are being introduced material in tns of kg/sq mm.

Zinc plated IS0 metric bolts and nuts are of parts must be expected. Although standardisation chromate passivated, a greenish

gold-bronze colour.

IDENTIFICATION

metric bolt or screw, made of

to

marks

to

indicate the strength grade e.g.

10.9,

12.9

or 14.9, where the first figure

HYDRAULIC FlTTlNGS

in

diameter can be

to

-

Metrication

steel

WARNING: Metric and Unified threaded hydraulic

parts. Although pipe connections to brake

M

system units incorporate threads of metric form,

those for power assisted steering are of UNF

identify the

type. It is vitally important that these two thread

forms are not confused, and careful study should be made of the following notes.

into motor vehicle manufacture and some duplication

-

khaki to must in the long run be good, it would be wrong not

to give warning cf the dangers that exist while UNF and metric threaded hydraulic parts continue

together in service. Fitting UNF pipe nuts into metric

ports and vice experience of the change from BSF to UNF indicated that there is no certainty in relying upon the difference in thread size when safety is involved.

To

provide permanent identification of metric parts is

not easy but recognition has been assisted by the following means. (Illustration

-

versa should not happen, but

A

Metric, B Unified.)

ST1035M

METRIC NUT IDENTIFlCATlON

1.

A

nut with an IS0 metric thread is marked on

one face or on one of the flats of the hexagon

with

the strength grade symbol Some nuts with a strength 4, marked and some have the metric symbol on the flat opposite the strength grade marking.

2.

A

clock face system is used as an alternative

method of indicating the strength grade. The

external chamfers or a face

marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

3.

A

dot is used to locate the 12 o’clock position and a dash the grade is above 12, o’clock position.

to

indicate the strength grade.

two

8,

12 or 14.

5

or

6

are also

of

the nut is

dots identify the

M

If

12

All

1.

2. The hexagon area

3.

metric pipe nuts, hose ends, unions and

bleed screws are coloured black. with the letter

Metric and

in shape.

’M’.

UNF

pipe nuts are slightly different

A

ST1033M

A

of

pipe nuts is indented

B

4

STt036M

ST1034M

The metric female nut is always used flared pipe and the metric male nut is always with a convex flared pipe.

REISSUED: FEB

1993

with

a trumpet

used

GENERAL FITTING INSTRUCTIONS

4. All metric ports in Cylinders and calipers have no counterbores, but unfortunately a few cylinders with UNF threads also have no counterbore. The situation is, all ports with counterbores are UNF, but ports not counterbored are most likely to be metric.

5. The coulour of the protective plugs in hydraulic ports indicate the size and the type of the threads but the function of the plugs is protective and not designed as positive

identification. In production it is difficult to use the wrong plug but human error must be mm and 3/8 in UNF pipe nuts used for 3/16 in (or taken into account. The Plug colours and 4,751 mm) pipe. The 3/8 in UNF pipe nut or hose can

thread sizes are:

UNF

x

RED GREEN YELLOW PINK

3/8 in

7/16 in 1/2 in 7/8 in

24 UNF

x

20

x

20 UNF

x

18 UNF

UNF

METRIC

BLACK GREY BROWN 14 x 1,5 mm

6.

Hose ends differ slightly between metric and

UNF. Gaskets are not used with metric hoses. The UNF hose is sealed on the cylinder caliper face by a copper gasket by the metric

hose seals against the bottom of the port and fine file and clean' thoroughly before there is a gap between faces cylinder.

Pipe sizes for UNF are 3/16

outside diameter. from new, as any indentation may indicate the

Metric pipe sizes are 4,75 mm pipe is exactly the same as 3/16 in pipe. mm pipe pipe is

Convex pipe flares are shaped differently for metric

sizes and when making pipes for metric equipment,

metric pipe flaring tools must

is

0.014 in smaller than 1/4 in pipe. 8 mm

0.002

in

10 x 1 mm 12 x 1 mm

in,

4,75

mm, 6 mm and 8 mm. onset of wear.

larger than 5/16

be

or

of

the hose and attempting to refit key.

1/4 in and 5/16 in suitable for refitting only

6

in

pipe.

used.

ST1032M

The greatest danger lies with the confusion of 10

be screwed into a 10 mm port but is very slack and easily stripped. The thread engagement is very weak and cannot provide an adequate seal. The opposite condition, a 10 mm nut in a 3/8 in port, is difficult and unlikely to cause trouble. The 10 mm nut will screw in 1 1/2 or 2 turns and seize. It has a crossed thread 'feel' and it is impossible to force the nut far enough to seal the pipe. With female pipe

nuts the position is of course reversed.

The other combinations are so different that there is

no danger of confusion.

KEYS AND KEYWAYS

1.

Remove burrs from edges

2.

Clean and inspect key closely; keys are

TAB WASHERS

1.

Fit new washers in all places where they are used. Always renew a used tab washer.

2.

Ensure that the new tab washer is same design as that replaced.

A

B

of

keyways with a

if

indistinguishable

of

the

ST1031M

REISSUED:

SPLIT

1.

2.

3.

FEB

PINS

Fit new split pins throughout when replacing any unit. Always fit split pins where split pins were

originally used. washers: there is always a good reason for

of

the use

All

split pins should be fitted as shown unless

otherwise stated.

a split pin.

1993

Do

not substitute spring

5

GENERAL FlTTlNG INSTRUCTIONS

NUTS UNIFIED THREAD IDENTIFICATION

1.

When tightening a slotted or castellated nut never slacken it back to insert split pin or locking wire except in those recommended surface of the bolt head. cases where this forms part of an adjustment.

If

difficulty

or nuts should

thickness reduced.

2.

Where self-locking nuts have been removed

is advisable

the same type.

is

experienced, alternative washers

be

selected, or washer

it

to

replace them with new ones of The component is reduced

1.

Bolts

A

circular recess is stamped in the upper

2.

Nuts

A

continuous line

of

the flats of the hexagon, parallel to the axis

of

the nut.

3.

Studs, Brake diameter for a short length at its extremity.

of

circles is indented

Rods.

etc.

to

the core

on

one

NOTE: Where bearing pre-load is involved nuts should be tightened in accordance with special instructions.

LOCKING WIRE

1.

Fit new locking wire of the correct type for all

assemblies incorporating

2.

Arrange wire tighten the bolt heads, or nuts, to which it is fitted.

SCREW THREADS

1.

Both UNF and Metric threads to ISO standards are used. See below for thread identification.

2.

Damaged threads must always Cleaning up threads with a die the strength and closeness of fit of the threads and is not recommended.

3.

Always ensure that replacement bolts are at

least equal

4.

Do not allow oil, grease or jointing compound

to

enter blind threaded holes. action on screwing split the housing.

5.

Always tighten a nut or bolt

recommended torque figure. Damaged

corroded threads can affect the torque

reading.

6.

To

check or re-tighten a bolt specified torque figure, of a turn, then re

7.

Always oil thread lightly before tightening to ensure a free running thread, except in the case of self

so

in

strength

-

tighten to the correct figure.

-

locking nuts.

it.

that its tension tends to

or

to

those replaced.

The

in

the bolt or stud could

or

first

slacken a quarter

be

discarded.

tap impairs

hydraulic

to

screw to a

the

or

1

ST1039M

3

2

6

REISSUED:

FEB

1993

RECOMMENDED LUBRICANTS,

FLUIDS

AND CAPACITIES

RECOMMENDED LUBRICANTS

AND

FLUIDS

REISSUED:

FEB

1993

1

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

2

REISSUED:

FEB

1993

CAPACITIES

RECOMMENDED

LUBRICANTS.

FLUIDS

AND

CAPACITIES

The following capacity figures are approximate and are provided as a guide only . using the dipstick or level plugs as applicable

Component Litres Imperial units

Engine sump oil Extra when refilling after fitting new filter Main gearbox oil. five LT230T transfer gearbox

Front differential ...................................................................................

Rear differential: Salisbury

Swivel pin housing oil (each) Cooling system Power steering box and reservoir fluid

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

-

speed

LT77S

.................................................................. 2,30

8HA

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

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

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

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

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

.

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

5,10

OS6 2,20

1,70

2,30

0,35

12,80

2,90

All

oil

levels must be set

9.00

pints

1.00

pint

3.90

pints

4.00 pints

3.00

pints

4.00 pints

0.60 pint

22.50

pints

5.0

pints

REISSUED:

FEB

1993

3

MAINTENANCE

WORKSHOP MAINTENANCE SCHEDULES

The following maintenance should be carried out by trained personnel in a fully equipped workshop. If the vehicle is operating in a remote area where workshop facilities are not available, maintenance and repair work should be carried out by experienced mechanics in safe conditions. Maintenance should normally be carried out at 7,500 miles (12,000 km) intervals or six months, whichever is first, as described in the following schedules, In severe conditions, such as deep mud or sand, or a very dusty atmosphere, the intervals should be reduced to monthly, weekly or even daily for some items. Ask your Dealer for advice.

WARNING: DO NOT use any lubricants solvents or sealants etc, before reading any warnings and instructions supplied with these substances, as they could be harmful if improperly used.

WARNING: Two wheel roller tests (Dynamometer) must be restricted to 5 km/hour (3 miles/hour). DO NOT engage the differential lock or the vehicle will drive off the roller test rig because the Defender 110 is a permanent 4 wheel drive.

WARNING: Use care when draining oil from the engine, gearbox and axles, if it is hot it could cause personal scalding.

WARNING: DO NOT work underneath the vehicle unless

it

is supported by heavy duty stands, otherwise the vehicle could move causing personal injury.

it

is

safely parked and the wheels chocked, or

REISSUED:

FEB

1993

1

ALL

MAINTENANCE

NORTH

AMERICAN MODELS

First 1000 miles (1600km) service

Renew engine oil. Check/top up transfer box oil. Renew front axle oil. Renew rear axle oil.

Renew steering swivel housing oil. Chec/top up power steering fluid. Check/top up transmission oil. Check operation Check/top up clutch and brake m/c fluid level. temperature gauges, warning indicators, lamps, Check for oil/fluid leaks from: horns and audio unit. Suspension, dampers and self levelling unit, engine Check operation of front and rear screen and transmission units, front and rear axles. wash/wipers.

Check brake pipes/unions for security, chafing leaks Check operation and security of rear view mirrors and corrosion. Check power steering system for leaks, hydraulic Check condition and security of seats, seat belt pipes/unions for security, chafing and corrosion. mountings, belts and buckles. Check fuel system for leaks. Check exhaust system for leaks, security and

Check fuel tank for condition and mounting bolts for damage. tightness Check cooling and heater systems for leaks, hoses Check tires for cuts, lumps, bulges, uneven wear, for security and condition. Check security and operation of park brake. Checkladjust tire pressures including spare. Check foot brake operation.

Check condition and security of steering unit, joints Drain flywheel housing and gaiters. Checkladjust steering Check front toe.

box.

only

Check positive crankcase ventilation system for leaks and hoses for security and condition. Check operation of throttle mechanical linkage. Check ignition wiring and

fraying.

Checkladjust all drive belts.

of

and for cracks and crazing.

Check tires comply with manufacturer’s specification. tread depth and road wheels for damage. Check/tighten road wheel retaining nuts.

HT

leads for security and

all instruments, fuel and

-re-

install plug.

2

REISSUED:

FEB

1993

CALIFORNIA

MAINTENANCE

California models

-

For maintenance after

45,000

miles (72,000

km)

we recommend that the

Required Maintenance’ is carried out in addition to the ’Recommended Maintenance’ list.

if

NOTE: The next service is due in six months

you drive less than

7,500

miles (12,000 km).

U.S.A.

REISSUED: FEB 1993

3

MAINTENANCE

4

REISSUED:

FEB

1993

MAINTENANCE

REISSUED:

FEB

1993

5

MAINTENANCE

REISSUED:

FEB

1993

7

MAINTENANCE

It is recommended that:

At

15,000 mile

clutch fluid should

At

37,500 mile

seals and flexible hoses should be renewed, all working surfaces of the master cylinder, wheel cylinders and

caliper cylinders should be examined and renewed where necessary.

At

37,500 mile (60,000 km) intervals remove all suspension dampers, test for correct operation, refit or renew

as necessary.

At

two

year intervals or at the onset of the second winter, the cooling system should be drained, flushed and

refilled with the required water and anti

(24,000

(60,000

km) intervals or every

be

completely renewed.

km) intervals or every 3 years, which ever is the sooner, all hydraulic brake and fluid,

18

months, whichever is the sooner, the hydraulic brake and

-

freeze solution.

The battery electrolyte level should be checked and topped up

once a year in tropical and sub

once every three years in temperate climates.

-

tropical climates

if

required

NOTE: Climatic and operating conditions affect maintenance intervals to a large extent: in many cases, therefore, the determination advice from an Authorised Dealer but the recommendations

of

such intervals must

be

left to the good judgement of the owner or

will

serve as a firm basis for maintenance

work.

Vehicles operating under arduous conditions will require more frequent servicing, therefore, at a minimum, the Maintenance intervals should be reduced by half.

For low mileage vehicles it is recommended that the maintenance is carried out at

The owner need not perform recommended maintenance manufacturer recall liability.

in

order

to

maintain the emission warranty or

6

months intervals.

SPECIAL OPERATING CONDITIONS

When the vehicle is operated

be

attention should

paid

in

extremely arduous conditions

to

all servicing requirements.

or

on dusty, wet or muddy terrain, more frequent

ADDITIONAL DAILY OR WEEKLY ATTENTION DEPENDING ON OPERATING CONDITIONS:

to

Check/top-up transfer box Check steering rubber boots for security and condition. Renew Check brake fluid level: consult your Dealer Clean brake discs and calipers.

Lubricate front and rear propeller shaft grease points and front sliding joint. Under tropical or severe conditions, particularly where sand of abrasive material.

Every week and every maintenance inspection check tyre pressures and inspect tyre treads and side walls.

Under arduous cross the extent of a daily check.

oil.

if

damaged.

if

any fluid loss

is

encountered, the sliding joints must be lubricated very frequently

-

country conditions the tyre pressures should

is

suspected.

be

checked much more frequently, even

to

prevent ingress

to

MONTHLY

Renew gearbox oil.

Renew transfer box oil.

6

Check air cleaner element and renew every

months or as necessary.

8

REISSUED: FEB

1993

MAINTENANCE

5.

LUBRlCATlON

This first part of the maintenance section covers

renewal of lubricating oils for the major units of the correct grade from a sealed container

vehicle and other components that require high mark on the dipstick and firmly replace lubrication, as detailed in the 'MAINTENANCE the filler cap. Reconnect the battery.

SCHEDULES' capacities and recommended lubricants. Vehicles operating under severe conditions of dust, sand, mud and water should have the oils changed and lubrication carried out at more frequent intervals

than that recommended in the maintenance

schedules. Draining of used oil should take place after a run

when the oil is warm. Always clean the drain and

-

level plugs before removing. In the interests of spanner as necessary.

filler safety disconnect the vehicle battery engine being started and the vehicle moved washer of the new filter, and half

inadvertently, while oil changing is taking place. oil. Then screw the filter on clockwise until the Allow as much time as possible for the oil to drain rubber sealing ring touches the machined

completely except where blown sand enter the drain holes. refit the drain plugs immediately the main bulk of oil has drained. filter. Stop the engine, allow the oil

Where possible, always refill with oil of the make back into the sump for a few minutes, then

and specification recommended in the lubrication check the oil level again and top up charts and from sealed containers.

.

Refer to 'SECTION 09' for

to

prevent the

or

dirt can face, then tighten a further half turn by hand

In

these conditions clean and only. Do not overtighten.

removed whilst the sump is empty, otherwise the

Clean the outside of the oil filler cap, remove

it

from the rocker cover and clean the inside.

6.

Pour in the correct quantity of new oil of the

to

the

RENEW OIL FILTER CAUTION: The engine oil filter must not be oil pump may have to be primed.

1.

Place an oil tray under the engine.

2.

Unscrew the filter anti-clockwise, using a strap

3.

Smear a little clean engine oil on the rubber

fill

with fresh

4. Run the engine and check for leaks from the

to

run

necessary.

if

WARNING: See ENGINE OILS under POISONOUS

-

SUBSTANCES

RENEW ENGINE OIL Drain and refill engine

1.

Drive vehicle to level ground.

2.

Run the engine to warm the oil; switch ignition and disconnect the battery for safety.

3.

Place an oil tray under the drain plug.

4. Remove the drain plug in the bottom

sump. Allow oil replace the plug and tighten to the correct

torque.

SECTION 01. INTRODUCTION.

off

of

to

drain away completely and

the

REISSUED: FEB 1993

9

MAINTENANCE

RENEW MAIN AND TRANSFER GEARBOX OILS DRAIN AND RENEW LT230T TRANSFER

GEARBOX OIL

DRAIN AND REFILL LT77S MAIN GEARBOX

1.

Drive the vehicle suitable container under the gearbox the old oil.

2.

Remove the gearbox and extension case drain.

drain plugs and allow the oil completely. Wash the extension case filter in

kerosene and refit washers, if necessary, and tighten correct torque.

to

level ground and place a container under the gearbox

to

catch oil.

2.

to

drain necessary, and tighten

3.

the

plugs using new approximate quantity

to

the until

Drive the vehicle

Remove the drain plug and allow the oil

Fit

the plug using a new washer,

Remove the filler-level plug and inject the

it

begins

level plug and tighten only to the correct torque, do not overtighten, wipe away any surplus oil.

to

level ground and place a

to

the correct torque.

of

the recommended oil

to

run from the plug hole.

catch the old

to

Fit

the

if

ST3084M

3.

Remove the oil filler-level plug and inject the approximate quantity of new oil of the correct make and grade until it begins to run out of

-

the filler

the correct torque. Since the plug has a tapered thread it must not

Wipe away any surplus oil.

level hole. Fit the plug and tighten to

be

overtightened.

ST1070M

10

REISSUED: FEB

1993

MAINTENANCE

RENEW SWIVEL PIN HOUSING OIL RENEW FRONT AND

1.

Drive the vehicle to level ground and place a

Drive the vehicle to level ground and place

container under each swivel housing to catch container under the axle

the used oil.

2.

Remove the drain plug and allow the

oil

to

2.

Using a spanner with a remove the drain plug and allow the oil

REAR

AXLE OIL

to

be drained.

13

mm

drain completely and clean and refit the plugs. drain completely. Clean and refit the drain

3.

Remove the oil filler-level plug and inject the plug.

of

recommended make and grade

oil until oil

3.

Remove the oil filler-level plug and inject new

begins to run from the level hole. Clean and oil of a recommended make and grade until

fit

the level plugs and wipe away any surplus begins

Oil.

filler-level plug and wipe away any surplus oil.

to

run from the hole. Clean and fit the

a

square drive

to

it

LUBRICATE PROPELLER SHAFTS

1.

Clean all the grease nipples on the front and rear propshaft universal joints, and sliding portion of the shaft.

2. Charge a low pressure hand grease gun with grease of a recommended make and grade and apply to the grease nipple. giving two to three strokes of the gun only to each nipple every 40.000 km (24,000 miles) intervals.

RE-ISSUED:

FEB

1993

11

MAINTENANCE

GENERAL MAINTENANCE AND ADJUSTMENT

This second part of the maintenance section covers the friction pads. adjustments and items of general maintenance as dictated However, only maintenance operations that are not fluid. included in the OVERHAUL SECTlONS of the

manual appear in this section. piston back into its bore, whilst ensuring that

by

the 'MAINTENANCE SCHEDULES'

.

EXAMINE AND RENEW DISC BRAKE FRICTION

4.

Withdraw the pad retaining pins.

5.

Remove the anti-rattle springs and

6.

Clean the exposed surfaces with new hydraulic fluid or brake cleaning

7.

Using piston clamp (18G

the displaced fluid does not overflow from the

reservoir.

of

672),

the

press each

withdraw

pistons

PADS

NOTE: Defender 90 has disc type brakes both front and rear

with disc type brakes at

brakes types are rear brakes on Defender piston calipers, The procedure for renewing

friction pads is the same for both types although there spring fitted, see Section 70.

Examine the friction pads for wear,

material is less than 3 mm thick they must be renewed as described instructions. Observe precautions

concerning asbestos:

at

the rear. Front brakes on both vehicle

fitted

may

be

a variation

axles.

with four piston calipers and the

Defender

the

front and drum type

90

are fitted with twin

in

the type of anti-rattle

or oil contaminated,

in

fitted

to

110

is fitted

if

the friction

the following

SECTlON 01

CAUTION: Friction pads must sets.

1.

Loosen wheel nuts, jack-up the vehicle, lower

onto axle stands. and remove the

2.

Clean the exterior

3.

Remove the split pins, or spring clips, the pad retaining pins.

of

me

calipers.

be

changed

in

wheels.

from

axle

8.

Smear the faces of the pistons with disc brake lubricant, taking care not to allow any to reach

the pad lining material.

9. Insert

10. Place the anti

11. Insert the pad retaining pins and secure with

12. Apply the foot brake pedal several times to

13. Check the fluid reservoir and top up if 14 Fit the road wheels and secure with the nuts

the

new friction pads.

-

rattle springs in position.

new split pins. locate the pads.

necessary Jack up the vehicle to remove the axle stands

and lower me vehicle to me ground Finally. tighten the road wheel securing nuts evenly. to the correct torque.

12

REVISED:

OCT

1993

MAINTENANCE

CHANGING THE HYDRAULIC BRAKE FLUID

In the service schedule it brake fluid is renewed at intervals or every eighteen months.

IS

recommended that the Pipes attached to the breathers on the axles

18,000

miles

(30.000

If

the following the axles to breath whilst the vehicle

km) terminate inside the engine compartment.

procedure is adopted air should not enter the mud and water.

AXLE BREATHERS

No

maintenance is required except

system. to ensure that the pipes

kinked, or split, or damaged in any other way

Proceed in the same way and order

1

bleeding the system, see

SECTION 70

clear plastic bleed tube is not available, interpose a short length bleed hose being used

of

glass tube into the

so

that the passage of

the fluid can be seen.

2.

Attach one end

of

the bleed hose

to

the bleed nipple of the wheel cylinder nearest master cylinder and immerse the

free

a glass vessel containing a small quantity brake fluid

so

that the end

of

the tube

as

for

.

If

a

to

the

end into

of

is

prevent proper breathing.

CHECK STEERING BALL JOINTS

Ball joints are lubricated for their normal life during manufacture and require no further lubrication. This applies only

if

the rubber gaiter has not become dislodged or damaged. The joints should be checked at the specified mileage intervals but more frequently

if

the vehicle is

used

under arduous conditions.

below the fluid level.

3.

Unscrew the bleed nipple screw about

-a-

turn, enough

half pumped out. system

if

the screw

Air

to

allow fluid to be

could be drawn into the

is

withdrawn too far.

do

This

IS

not

become blocked,

allows

traversing

to

4

Pump-out most, but not all, of the fluid from the reservoir by continuously depressing and releasing the foot pedal. Do not, however, allow the reservoir to empty completely.

5. Top-up the reservoir with new, unused fluid. of the correct specification, from a sealed container. See SECTION 09 .

6. Ensure that the reservoir is kept topped

-

up and continue bleeding until the old and discoloured fluid is dispelled and the new fluid is seen passing through the clear bleed hose or glass tube. Continue to bleed for two full

strokes of the pedal and then close the bleed nipple whilst the pedal is depressed.

7 Repeat the above procedure at the remaining

wheel cylinders in turn.

-

8. Top

up the reservoir and road test the vehicle.

RE-ISSUED: FEB

1.

Check ball joint movement joint assembly.

1993

for

wear

in

the joints by moving the

up

and down vigorously.

is

apparent renew the complete

If

free

‘7

MAINTENANCE

CHECK FRONT WHEEL ALIGNMENT

Recognised front wheel alignment tracking equipment should be used

See

SECTION 04

for wheel alignment data. Before

to

perform this check.

checking the alignment make the following checks:.

a.

The vehicle is on level ground.

b.

The vehicle

c.

The tire pressures are correct. cam.

d.

The wheels run true and are not damaged or

is

not loaded.

buckled.

e.

The track rod is not damaged ball joints are not worn.

joints are assembled

plain and are central

in

or

bent and the

Also

check that the

the same angular

their housings. See

SECTION 57.

1.

Set the road wheels to the straight ahead

position and move the vehicle forward a short distance at least

two

revolutions of the

wheels.

2.

Set up the tracking equipment to the

manufacturers instructions.

3.

Position the trammel probes on the inner face

of

the wheel, not the rims,

if

the latter are

damaged.

4.

Check the alignment as instructed

by

the equipment manufacturers and repeat the check on required follow the instructions

SECTION

the

opposite wheel. If adjustment

57.

in

steering

is

ADJUST REAR BRAKES DEFENDER 110 ONLY

1.

Raise up vehicle and lower onto axle stands.

2.

Each shoe is independently set by means

of

hexagon adjuster. Check that the wheel turns freely and turn one adjuster until the shoe locked against the drum. Slacken off the adjuster sufficiently

approximately

3.

Repeat the above procedure

two

for

the wheel to turn freely

serrations

on

the snail

for

the second

brake shoe and the opposite wheel.

4.

Remove the axle stands and road test the

vehicle brakes.

a

I

S

14

REVISED:

OCT

1993

MAINTENANCE

6.

ADJUST TRANSMISSION BRAKE (Handbrake)

Set the vehicle on level ground and chock the handbrake shoes just clear the drum.

1.

wheels.

2.

Release the handbrake fully.

3.

Remove the clevis pin connecting the handbrake lever

end.

to

the relay at the gearbox

CAUTION: DO NOT over adjust the handbrake, the drum must be free to rotate when the handbrake is released, otherwise serious damage will result.

DRAIN FLYWHEEL HOUSING

4.

Turn the adjuster on the back plate clockwise until the shoes are fully expanded against the drum.

Fit the clevis pin, washer and a

7.

Slacken the adjuster 1 or 2 notches until

8.

Apply the handbrake gradually. The drum

should still rotate on the first ratchet and start

to

come on at the second ratchet.

1.

The flywheel housing can be completely

sealed

to

exclude mud and water under severe wading conditions, by means of a plug fitted in the bottom of the housing.

2.

The plug should only be fitted when the

vehicle is expected

to

muddy work.

3.

When the plug is in use periodically and any oil allowed

before the plug is replaced.

4. When the plug

is

not in use, it must be stored

as shown.

NEW

split pin.

do wading

it

must be removed

to

or

drain

very

off

5. Adjust the outer sheath of the handbrake

cable by means

of

the

two

locknuts at the gearbox end until the holes in the clevis on the inner cable line up

the hole

in

the

with

relay lever

REISSUED:

ST3078M

FEB

1993

15

MAINTENANCE

FILTERS FUEL FILTER

AIR

CLEANER ELEMENT

Removing

1.

Release the three clips and remove the inlet regarding fuel handling are strictly adhered to

tube. when carrying

2. Remove the nut and end plate.

3.

Withdraw element and discard.

Refitting precautions are taken to prevent fire and

4.

Insert the new element and reassemble the unit in reverse order

ST3413M

to

removal.

Remove and refit

WARNING:

precautions given

WARNING:

during this operation. Ensure that all necessary

explosion.

Removing

1.

Depressurise the fuel system.

2.

The fuel filter is located on the right-hand chassis side member forward of the fuel tank filler neck. Access through the right

3.

Clamp the inlet and outlet hoses fuel spillage when disconnecting the hoses.

4. Loosen the

hoses

5.

Release the single nut and bolt securing the filter and clamp and remove the filter.

Ensure that the fuel handling

in

Section

out

the following instructions.

The spilling of fuel

-

hand rear wheel arch.

two

fuel unions and remove the

from

the filter canister.

01

-

Introduction

is

unavoidable

to

the filter is gained

to

prevent of

AIR CLEANER

The

dump

air cleaner and support bracket.

Checking

1.

Squeeze open the dump valve and check that the rubber

2.

If

necessary remove the dump valve to clean

the interior.

3. Fit a new valve

condition.

DUMP

valve provides an automatic drain for the

is

VALVE

fitted in the base of the air cleaner

is

flexible and in good condition.

if

the original

is

in

a

poor

Refitting

6.

Fit a new filter observing the direction of flow

arrow on the canister.

7.

Tighten the single nut and bolt.

8. Fit the inlet and outlet hoses. Tighten the

-

unions to a torque of (27

9.

Refit the fuel pump relay. Reconnect the

battery and recode the radio.

10.

Start the engine and inspect for fuel leaks

around the hose connections.

34Nm).

16

REISSUED:

FEB

1993

MAINTENANCE

Charcoal canister Defender

110

Remove

1.

Disconnect battery negative lead.

2.

Disconnect both purge lines.

3. Release canister from its mounting bracket.

3. Disconnect pipe.

4.

Loosen bolt and remove charcoal canister

3

Refit

4.

Reverse the removal procedure, ensuring that

is

the canister

securely located

in

its mounting bracket and both purge lines are fitted correctly to the canister.

WARNING:

charcoal canister or

The

use

of

compressed air to clean a

to

clear a blockage

in

the evaporative system is highly dangerous. An explosive canister may when compressed air passes

gas

present

be

ignited

in

a fully saturated

by the heat generated

through

the canister.

Charcoal canister Defender

90

Remove

1.

Disconnect battery negative lead.

2. Pry out purge valve.

Refitting

5.

Reverse the removal procedure.

POSITIVE CRANKCASE VENTlLATION INTAKE FILTER

1.

Pry

the filter holder upwards to release

it

from

the rocker cover.

2.

Discard the sponge filter.

Fit new filter

3.

Insert a new filter into the plastic body

4.

Push the filter holder onto the until

it

clips firmly into place

rocker

cover

REVISED: OCT 1993

17

MAINTENANCE

CLEAN PLENUM CHAMBER VENTILATION PASSAGEWAY

7. Any remaining consolidated matter can

dislodged using a piece pipe cleaner. Finally the passageway must

The cleaning

of

the plenum chamber ventilation again be blown out to remove any remaining

passageway can be carried out without removing the debris.

plenum chamber from the ram housing.

8.

Remove the small

crankcase ventilation hoses and check that

CAUTION:

from the passageway passing beyond the throttle

Care must

be

taken to prevent debris is free from blockages, clean as necessary

9.

Refit the ‘T’ piece and hoses, tighten the hose

valve disc. clamps securely.

WARNING:

performing this operation. Ensure that debris not blown into the atmosphere which could

harmful to other personnel within the vicinity.

Safety glasses must

be

worn when

is

be

CLEAN POSITIVE CRANKCASE VENTILATION

BREATHER FILTER

1.

Release the hose clamp and pull the hose the canister.

1.

Disconnect the battery negative terminal. 2. Unscrew the canister and remove

2.

Release the hose clamp and remove the hose

from the plenum chamber inlet neck.

Remove the crankcase ventilation

3.

of

the side

4.

Insert a piece of lint free cloth down the screen within the canister,

the plenum chamber.

hose from end

throttle valve bore to prevent debris passing beyond the throttle valve.

5.

Place a cloth over the tube protruding from

of

the side

the plenum from which the

rocker cover.

3.

Remove the large

of

the canister.

4. Visually

inspect

fit a new assembly, condition clean the screen as follows:

ventilation hose was removed to prevent debris from the passageway being blown into the atmosphere.

of

soft

bent

'T'

piece between the

'O'

ring from the threaded

the condition

if

of

if

in

poor condition

in an acceptable

wire

if

from the

the wire

or

be

a

it

off

18

6.

Use a compressed air nozzle

to enable the passageway to

line

with a slim bent

cleaned out from within the throttle valve bore.

5.

Immerse the canister solvent and allow dissolve and loosen within

6.

Remove canister from solvent bath and allow to dry out in still air.

WARNING:

remove any remaining solvent or particles of debris within the canister as this could cause fire or personal injury.

be

Refitting the breather/filter

7

Fit a new rubber

8.

Screw the canister into the rocker tight only.

9. Refit hose and tighten hose clamp securely

RE-ISSUED: FEB 1993

in

a

small amount

time

tor the solvent

any

engine fume debris

of

10

the canister.

Do not use a compressed air line to

'0'

ring.

cover

hand

I

MAINTENANCE

GENERAL MAINTENANCE AND ADJUSTMENTS

OF

CHECK/ADJUST OPERATION

ALL WASHERS

AND TOP-UP RESERVOIR

1.

Check the operation and headlamp washers.

2.

Adjust jets

or

very fine sharp implement into the jet orifice

and maneuvering

3.

Unclip the reservoir cap.

4.

Top up reservoir to the bottom Use a screen washer soIvent/anti-freeze in the reservoir, this flies and road film and protect against freezing.

if

necessary by inserting a needle

of

the filler neck.

will

of

windscreen, tailgate

to

alter the jet direction.

within

25mm

assist in removing mud,

(1

in)

below

IGNITION Spark plugs

1.

Take great care when fitting spark plugs not

-

to cross damage

2. Check or replace the spark plugs as applicable.

3.

It is important that only the correct

spark plugs are used

4. Incorrect grades

overheating and engine failure.

thread the plug, otherwise costly

to

the cylinder head

for

of

plugs may lead

will

result.

replacements.

to

type

piston

of

Fitting

RR1876E

H.T.

leads

9.

Ensure that replacement refitted in their spacing cleats in accordance

with the correct layout illustrated. Failure in cross-firing between two closely fitted leads which are consecutive in the firing order.

to observe this instruction may result

H.T.

leads are

To

remove spark plugs proceed as

5.

Disconnect the battery negative lead and

remove the leads

6. Remove the' plugs

RR2171E

7.

Set

the electrode gap to the recommended

clearance.

8. When pushing the leads onto the plugs,

ensure that the shrouds are firmly seated the plugs.

from

and

the

washers.

follows:

spark plugs.

on

RE-ISSUED:

FEB

1993

19

MAINTENANCE

CLEAN AND LUBRICATE V8 ENGINE ELECTRONIC DISTRIBUTOR every 40,000 km (24,000 miles)

WARNING:

involves very

personnel and wearers devices should not be allowed near any part the high tension circuit.

1.

Remove the distributor cap and rotor arm and wipe inside with a nap disturb the clear plastic insulating cover which

protects

2.

Apply three drops rotor spindle

The electronic ignition System recirculated

high

the magnetic pick-up module.

voltages. Inexperienced The system consists

of

medical pacemaker should be examined at the same mileage intervals

-

free cloth.

of

clean engine oil to the

Do

of

not

AIR CONDITIONING SYSTEM DEFENDER 110

The air conditioning system operates in conjunction

with

the vehicle heater

or

fresh air to the vehicle interior

as the heater system:

A.

Engine mounted compressor.

B. Condenser in front

C.

A

receiver/drier in front

the condenser.

D.

Evaporator/heater unit in engine compartment

to

provide dried cooled

of

the following units which

of

the radiator.

of

and to the right

of

3.

Fit the rotor arm and distributor cap and

ensure that the

secured with the

cap is property located and

two

clips.

1.

Compressor: Check the pipe connections tor leakage and the hoses tor swelling Check that the drive belt is correctly tensioned

2. Condenser: Using an air line. or a water hose, dean the exterior of the condenser matrix. Check the pipe Connections for signs of leakage.

20

REVISED

OCT

1993

3.

Receiver/drier: Check the pipe connections

for signs while the system is operating and are present contaminated

of

leakage. Examine the sight glass

if

bubbles

it

indicates that the system is

with

air

or

water and

will

require

CHECK BRAKE FLUID RESERVOIR

purging. reservoir.

ST3150M

MAINTENANCE

1.

Check the fluid level in the fluid reservoir observing the level in relation to the 'MIN’

'MAX'

2.

If

outside of the filler cap and top clean fluid from a sealed container. fluid recommended in cap.

marks on the side

the level

is

below the

of

the translucent

'MAX'

mark clean the

-

up with new.

'SECTION 09'.

by

Use

only

Refit the

or

4.

Evaporator: Examine the pipe connections for

leaks.

WARNING:

high

at If any repair or servicing work following the above inspections,

carried

The air conditioning system

is

filled

pressure with a potentially toxic material.

is

necessary

it

must

only

be

out

by a qualified air conditioning on the side

engineer who must wear protective goggles and follow the WARNINGS and CAUTIONS given

in

SECTION 82.

CHECK

C

L

U

T

C

H

F

L

U

I

D

RESERVOIR

1.

Clean and remove the reservoir cap and observe the fluid level in relation to the marks

of

the

reservoir.

2.

Top-up a sealed container and specification -

if

necessary with new, clean fluid

of

a recommended

see

'SECTION 09'.

cap.

Refit

from

the

RE-ISSUED:

ST3141M

FEB

1993

21

MAINTENANCE

Do

POWER STEERING FLUID RESERVOIR

WARNING:

engine is hot because the cooling system

1.

Clean and remove the reservoir cap.

2.

Check that the fluid the dip

stick.

I

S

Top-up

up to the lower mark on

if

necessary and refit

cap.

pressurised and personal scalding could result.

1.

When removing the filler cap, first turn little way very gently and gauge any pressure that may be behind escape slowly before fully releasing the cap.

2.

With a cold engine, the coolant level should

be just to the top of the level indicator post

situated in the expansion tank below the filler

hole.

BATTERY

Check Specific Gravity The specific gravity of the electrolyte should be

checked using a battery hydrometer. The readings

ST445

should be as follows: Temperate climate below 26.5°C (80°F) as commissioned for service, fully charged 1.270 to

1.290 specific gravity.

CHECK COOLING SYSTEM COOLANT

As expected during normal sewice, three-quarter charged 1.230 to 1.250 specific gravity.

Refer to the 'COOLING SYSTEM' section for details If the specific gravity should read between 1.190 to

-

of anti-freeze and to SECTION 09 for anti

freeze 1.210, half-charged, the battery must be bench protection quantities. charged and the electrical equipment in the car With a cold engine, the expansion tank should be should be checked. approximately half full. Tropical climate above 26.5°C (80°F) as

commissioned for service, WARNING: Do not remove the filler cap when the 1.230 specific gravity. engine is hot because the cooling system is As expected during normal sewice, three-quarter pressurised and personal scalding could result. charge 1.170 to 1.190 specific gravity.

If the specific gravity should read between 1.130 to

1. To remove the filler cap, first turn it 1.150, half

-

clockwise a quarter of a turn and allow all

anti pressure to escape, before turning further in

charged and the electrical equipment on the car

should be checked.

me same direction to lift it off. When replacing the filler cap it is important that it is tightened down fully, not just to the first stop. Failure to tighten the filler cap properly may result in water loss, with possible damage to the engine through overheating.

not remove the filler cap when the

it

it.

Allow all pressure

fully

charged 1.210 to

-

charged, the battery must be bench

is

a

to

22

REVISED:

OCT

1993

MAINTENANCE

Check and Top-Up Electrolyte Level

Wipe all dirt and moisture from the battery

1.

top. to the servo.

2.

Remove the filler cover, sufficient distilled water the top

Replace the filler plugs or manifold lid.

3. Avoid the use

examining the cells.

4.

In hot climates it

the battery at more frequent intervals.

5.

In very cold weather

vehicle is used immediately after topping up,

to

mixed precaution may result in the distilled water

freezing and causing damage

of

separators.

of

will

ensure that the distilled water is thoroughly

with

the electrolyte. Neglect

If

necessary add

to

raise the level to

a naked light when

be necessary to top up

it

is essential that the

of

to

the battery.

Battery terminals

6. Remove battery terminals, clean, grease and refit.

7.

Replace terminal screw: do not overtighten.

Do

not use the screw

terminal.

8.

Do NOT disconnect the battery cables while the engine semiconductor devices may occur. It inadvisable to break in the alternator charging and control circuits

while the engine

9.

It

is

connections regulator, as any incorrect connections made when reconnecting cables may cause irreparable damage

devices.

IS

running

essential

to

is

to

the battery, alternator and

for

pulling down the

or

damage to alternator

or

make any connection

running.

observe the polarity

to

the semiconductor

is

this

also

of

RENEW

BRAKE

1.

Remove the nuts securing the master cylinder

2.

Release the clip retaining the brake pipe to

the clutch pipe.

3.

Separate the master cylinder from

4

Disconnect the vacuum hose from the servo.

5.

Disconnect the Lucars from the stop lamp

switch

6.

Remove the blanking grommets from the

pedal box.

7.

Remove the split pin from

withdraw the clevis pin and washer

at

the rear

SERVO

FILTER

of

the pedal

the

box.

the

servo.

clevis and

CAUTION:

it should

If

bo

a

new

the

battery

same

is fitted to the vehicle,

type

as fitted to the

vehicle when new. Alternative batteries may vary

or

be

leads

in sire and terminal positions and this could possible fire hazard

if

the terminals

come into contact with the battery clamp

assembly. When fitting a new battery ensure that

of

the terminals and leads are clear

the battery

clamp assembly.

RE-ISSUED:

a

8.

FEB

Remove the four nuts securing the servo to

the pedal box and remove the servo

1993

23

ST1533M

9.

10.

11.

MAINTENANCE

Pull back the dust cover. Release the end-cap.

Cut the filters to remove them from the shaft.

ST1835M

DRIVE

BELT TENSIONING

WARNING:

Do not attempt

to

check belt tension or make adjustments with the engine running. Serious

injury

could result.

Each drive belt should be tight enough without undue strain on the bearing. Using moderate finger pressure at the point indicated

illustration, belts should deflect

0.5

mm

Deflection beyond this limit may cause whining or knocking noise and intermittent drive.

FAN/WATER PUMP DRIVE BELT ADJUSTMENT

1.

Loosen

12.

Clean the filter seating and fit the new filters adjust the wheel position until the correct

the

jockey wheel securing bolt and

noting that they must be cut to fit over the tension is obtained. shaft 2. Tighten the securing bolt and recheck the

-

13

Fit the end

cap and dust cover and refit the deflection. servo and master cylinder to the vehicle reversing the removal procedure. Use a new split pin to secure the clevis.

14 Test the brakes

THROTTLE PEDAL ADJUSTMENT

per

to

25

in

a

dnve

the mm. loud

1.

After renewing the throttle cable. remove any

slack in the cable by adjustment of the cable adjuster at me engine end.

2. Depress the throttle pedal, by hand, to the full extent of the throttle linkage, and adjust the

pedal stop screw to take up all clearance between the screw and scuttle panel. Make

sure that no strain is placed upon the throttle linkage.

24

REVISED:

OCT

1993

MAINTENANCE

AIR CONDITIONING COMPRESSOR DRIVE BELT DEFENDER

110

ADJUSTMENT

1.

Loosen the Jockey wheel securing bolt and adjust the wheel position until the correct

tension is obtained. Tighten the securing bolt adjustment bolt. and recheck the deflection

ST3424M

ALTERNATOR AND POWER STEERING PUMP DRIVE BELT ADJUSTMENT

POWER STEERING PUMP DRIVE BELT

Before adjustment of the steering pump belt

out,

the alternator drive belt must be loosened

facilitate accurate adjustment.

1.

Loosen the steering pump pivot nut and

2.

Ensure the pump

mounting.

DO

I

S

free to rotate

NOT

lever pump, loosen fixings

further if necessary.

3.

Carefully lever against the pump bracket tension the belt. Where access is restricted, a

with

lever

one end cranked 5°

to

10°

fed down between the water pump and distributor. Place the lever against the steering pump bracket, carefully levering from the

water pump/front cover

is

carried

on

may be

to

the

to

An additional pulley, bolted to the front of the steering pump pulley is used as a guide for the alternator drive belt. Before adjustment steering pump must

be

belt

is carried out, the alternator belt

loosened to facilitate accurate adjustment.

of

the

Before adjusting the alternator drive belt ensure the steering pump belt is correctly adjusted.

CAUTION:

pump

in

casing.

oil

leaks.

4.

Check the belt tension at the mid-point longest span, the

per

Tighten the steering pump adjustment bolt and pivot nut.

5.

Recheck the

6.

Carry out alternator belt tensioning

Do

25

not

Damage

mm

of

belt

lever against the steering

to

the casing may result

of

belt

should deflect

belt

run between pulley centres

0.5

tension.

the

mm

RR3909M

1.

2.

3.

4

Alternator drive belt

Steering pump drive belt Steering pump and guide pulley Alternator drive belt tensioner

REVISED: OCT

1993

25

MAINTENANCE

ALTERNATOR

Before adjusting the alternator drive belt, ensure that the steering pump drive belt is correctly tensioned.

A

positive drive tensioner is fitted to provide greater

accuracy when setting the alternator belt. The tensioner eliminates the need to lever the alternator

when adjusting the belt tension.

1.

Loosen the alternator pivot bolt and the bolt The control unit colour is brown, mounted securing the alternator to the tensioner. brown plug, 'EMISSION MAINTENANCE

Loosen the

2.

securing the tensloner to the water pump unit. A tamperproof label is attached to the top bracket. unit.

3.

Rotate the tensionerlead screw either anti

tighten the drive belt until the correct tension after the required maintenance has been carried out is obtained. and a new tamperproof label fitted

DRIVE

-

clockwise to slacken

BELT

two

tensioner nuts and the bolt REMINDER' is embossed in white on the side

or

clockwise to The emission maintenance reminder must be

RESET EMISSION MAINTENANCE REMINDER

The emission

activate at 52,500 and and will illuminate a red 'Service Engine' warning light in the instrument panel.

The control unit panel,

of

North America dealer. This Emission maintenance reminder is part of the Emission Control System, refer to section

The unit

maintenance reminder is designed

IS

located behind the instrument

17.

can

be reset as follows:

105,000

miles respectively

by

to

on

a

of

the

of

the

reset

a Land Rover

NOTE: Where possible the

belt

tension

should

be

checked using a recognised tensioning gauge.

The

to

4

5.

correct

158

Tighten the alternator pivot bolt. the two bolts securing the tensioner and the two tensioner nuts Recheck the belt tension.

If a new drive belt has been fitted. run the engine at fast idle for 3 to 5 minutes, stop engine and recheck belt tension.

tension using

Hz.

a

Clavis

gauge

is

152

1.

Remove the fixings and lower the lower dash panel.

2. Identify the control unit and remove

plug.

3.

Remove the tamperproof label to reveal the access hole for resetting.

it

from the

26

REVISED:

OCT

1993

4.

Using a small probe into the access hole and momentarily electrically short between the reset pins within the unit.

5.

Refit the control unit ignition, the in the instrument panel part of the unit’s inbuilt check feature, unit has been

will

go

out after a few seconds. Should the warning light remain illuminated, repeat the resetting procedure.

6.

Fit a new tamperproof label.

7.

Endorse the Passport

thin

metallic probe, place the

to

the plug, switch on the

’SERVICE ENGINE’

will

initially light up as

reset

correctly the warning light

to

service.

warning light

if

MAINTENANCE

the

REISSUED:

FEB

1993

27

DESCRIPTION

The

V8

engine has cast aluminium cylinder heads and cylinder block. The which are pressed down pistons transmit the power through the connecting rods centrally located camshaft via an inverted tooth chain.

to

stops

in

the block, are set at

to

a

ENGINE

two

banks

90°

to one another. The three ringed aluminium

cast

iron

five bearing crankshaft, which drives the

of

steel cylinder liners

The electronic ignition distributor and lubrication oil pump are driven by a skew gear

camshaft. The overhead inlet and exhaust valves are operated by rocker shafts, pushrods and self adjusting hydraulic tappets.

Multipoint fuel injection ensures that engine performance, economy and exhaust emissions are automatically

correct

for

the demands

of

highway and

off

road operation.

off

the front

of

the

ENGINE

RR3627M

1.

Cylinder block

2. Pistons and gudgeon pins (8)

3. Connecting rods (8)

4. Core plugs

5. Camshaft

6. Dipstick

7. Camshaft key

8. Timing chain

9. Camshaft sprocket

10. Distance piece Distributor/oil pump drive gear

11.

12.

Distributor Oil pump gears

13.

14. . . Front Cover

19. Crankshaft sprocket key

20. Crankshaft

21. Centre main bearing shells (2)

22. Crankshaft rear oil seal

23. Spacer

24. Adaptor plate

25. Rear main bearing cap, shell and side seals

26. Connecting rod caps

27. Main bearing caps and shell bearings

28. Oil pump cover

29. Oil pressure refief valve

30. Oil cooler/filter adaptor

31. Oil filter

32. Oil pump suction pipe/strainer

15. Front cover oil seal 33. Sump

16. Water pump

17. Crankshaft damper/pulley

18. Crankshaft sprocket

ENGINE

RR3524M

34. Cylinder heads

35. Rocker covers

36. Oil separator

37. Rocker shafts

38. Hydraulic tappets (8) 50. Thermostat cover

39. Pushrods (8)

40. Rocker brackets (8)

41. Rocker arms (4) left and

42. Rocker shaft springs (6)

43. Inlet manifold

44.

Plenum chamber lower

45. Ram pipes (8)

(2)

46. Plenum chamber upper 47, Air filter

48. Oil filler

49. Thermostat

51. Inlet valve spring, cap, seal

52.

Exhaust valve spring, cap, collets

(4)

right 53. Inlet valve and seat (8)

54. Exhaust valve and seat (8)

55.

Tappet cover gasket and seals

56. Cylinder head gaskets (2)

57.

Valve guides (16)

and

collets

(8)

ENGINE

Lubrication

The

V8

via the distributor drive shaft. The oil pump gears are housed in the timing cover and the pressure relief valve, warning light switch and filter are

Oil drawn through the centrally located steel gauze strainer in the sump, is pumped under pressure through oil cooler located before being distributed from the main gallery via drillings, to the various components in the engine.

Lubrication to

face, which are timed to align with holes in the big end journals on the Dower and exhaust strokes.

system

full flow lubrication system uses an external gear pump which

fitted

to the gear cover.

in

the lower half of the main coolant radiator. The cooled oil then passes through the filter,

the

thrust side of the cylinders

is

by

oil

grooves machined in each connecting rod big end joint

is

driven from the front of the camshaft

Lubrication system

1

Oil to cooler

2

Oil from cooler

Distributor/oil pump drive and timing chain

lubrication

The distributor/oil pump drive, and timing chain lubricated from the camshaft front bearing. The feed

to

the timing chain

sprocket, key and spacer where

is

channelled along the camshaft

it

sprays onto the

chain.

ENGINE

RR3528M

RR3526M

1

Bearing

2

Camshaft

3

Key

4

Cam

gear

5

Spacer

6

Distributor oil pump drive gear

Filtered oil

Lubrication pressure is controlled by the pressure relief valve

which allows excess pressure

to

E

escape into the pump suction gallery D. The oil is then pumped through the cooler via connections

A

and B before passing through the anti-siphon valve

is

and into the filter. Filtered oil engine bearings by port

C.

supplied to the

Unfiltered oil

Any blockage

-

pass valve and maintain an un-filtered

by

to

the bearings.

of

the filter element will open the

F

oil

supply

RR3529M

ENGINE

Hydraulic tappets

The purpose maintenance

exhaust valves. It achieves its designed purpose by tappet

utilizing engine oil pressures mechanical clearance between the rockers and the valve stems.

Operation

During normal operation, engine oil pressure in the upper chamber non

-

return ball valve 2 and into the lower (high

pressure) chamber 3. When the cam begins

resistance the push rod and seat to move downwards inside the outer. This slight downward movement the ball valve in the high pressure chamber 3

that the push rod opens the cylinder valve fully.

of

the hydraulic tappet is

free

and quiet operation

to

1,

passes through the

to

lift

the outer sleeve

of

the cylinder valve spring felt through

5,

causes the inner sleeve

of

the inner sleeve

2

and increases the hydraulic pressure

,

sufficient

to

of

the inlet and ensures that the cylinder valve fully closes when the

eliminate the

present

6,

to

provide equalize the pressure in both chambers which

4,

the

6,

closes

ensure

As the tappet assembly moves

cam

1

2

3

4

5

6

7

8

off

the peak of the

to

the closing side, the ball valve 2 opens

is

on the back

of

the cam.

6

RR3531M

Upperchamber Non-return ball valve Lower chamber (high pressure)

Outer sleeve

Pushrod seat Inner sleeve Spring Clip

to

ENGINE

ENGINE FAULT DIAGNOSIS ENGINE OIL PRESSURE TEST

Service tools:

LRT

-12-

052: Pressure test equipment

WARNING:

equipment, workshop.

WARNING:

oil

will

equipment scalding.

Test

1.

Check lubricant is to correct level. open).

2.

Place vehicle on a ramp.

3. Disconnect battery negative terminal and 3. Disconnect both coil negative remove oil pressure switch.

4.

Fit the test gauge. reading stabilises.

5.

Connect battery terminal.

6.

Start and run engine to normal operating temperature.

7.

At

minimum engine oil pressure reading should rings or valves may

be

8.

If there system. See Service schedule.

9.

If the pressure is overhaul oil pump.

Use suitable exhaust extraction

if

test

is

being carried out

If

vehicle has been running, engine

be

hot,

care must

to

prevent personal injury due to

a steady engine speed

-

1.76

kg/cm².

is

no oil pressure check for air lock

be

taken when fitting

of

2400

low,

see Remove and

in

rev/min

in

NOTE:

engine performance by over hydraulic tappets causing the valves to be held open, see Lubrication system.

CYLINDER COMPRESSION - TEST

Equipment: Compression pressure gauge

Test

-

Excessive lubrication pressure can effect

1.

Start and run engine until normal engine

operating temperature is achieved (thermostat

2.

Remove all spark plugs.

4.

Insert compression gauge, crank engine until

5.

Expected readings, throttle fully open, battery

fully

charged

6.

If

compression is appreciably less than correct

figure, or varies by more than

7.

Low pressure in adjoining cylinders may

indicate a faulty head gasket.

170 - 180

be

-

pressurising the

(WB)

leads

psi

10%,

faulty.

piston

RR2354E

4

ENGINE

Excessive or obtrusive noise from the engine

compartment originates from three main sources:

A.

B. External components emit the greatest variety

C.

Engine internal mechanical noises. Single

particularly when engine

system.

1.

NOISES

The exhaust system, which makes an YES unmistakable and easy

of

noises, but are also easy to diagnose by simply disconnecting the appropriate drive YES belt. examine for metallic

Engine internal mechanical noises which can

vary in volume and pitch and may be a 3. combination of, tapping rumbling, are the most difficult

The following is therefore a guide to diagnosis diagnosis, short out the

of

engine internal mechanical noises only.

or

multiple, light tapping noise,

Is

engine oil level correct? front pulley. Temporarily release the drive

NO

YES

-

Top up Continue. stethoscope

to

diagnose noise.

is

cold.

to

correct level.

-

knocking or YES

to

diagnose. bearings. To confirm

See

Lubrication

Heavy knocking noise (particularly on load and when engine is hot). See Lubrication system.

1.

Is

engine oil level correct?

NO

-

2.

Is

the lubricating pressure correct?

-

NO

-

Is

the oil contaminated

-

4.

If

noise is not conclusively diagnosed, check

the security belts to reduce general noise level and use

Top up Continue.

See Engine oil pressure test.

Drain engine oil and filter, and

contamination.

Suspect faulty big end

ignition turn. The noise

or be reduced when the cylinder is shorted out.

of

to

locate source of noise.

to

correct level.

with

metal particles?

to

each spark plug in

will

disappear

with

the faulty big end

the flywheel and crankshaft

a

2.

Is

the lubricating pressure

NO

-

YES

-

3.

To confirm diagnosis, remove the rocker covers and with the engine idling, insert feeler gauge of 0,015mm between each rocker and valve stem. operating mechanism noise when the feeler gauge

Rocker shafts and valve gear.

See Engine oil pressure test. Suspect valve operating mechanism. 1.

correct?

A

faulty valve

will

emit a different

is

inserted. See examine for metallic

Heavy rumbling acceleration). See Lubrication system.

Is

engine oil level correct?

-

NO

YES

-

noise

Top up

Continue.

(particularly during hard

a

2.

Is

the lubricating pressure correct?

NO

-

YES

-

3.

Is

the oil contaminated with metal particles?

YES

-

See Engine oil pressure test.

Drain engine oil and filter, and

contamination.

Suspect faulty main bearings.

If

noise is not conclusively diagnosed, check the security of the flywheel and crankshaft front pulley. Temporarily release the drive belts reduce general noise level and

use a stethoscope source of noise.

to

correct level.

to

locate

ENGINE

ENGINE STARTING PROBLEMS

NOTE: References to the Electrical Trouble Engine runs at high speed Shooting Manual (ETM) in the following (stops) paragraphs are to the Range Rover ETM. Engine idle speed erratic Engine starts However, only the specific circuits referred to in the following paragraphs are applicable to the Defender.

Engine fails

1.

Is

NO

YES

If

starting at

Engine cranks but fails to start

1.

Is

NO

If

YES

2.

Is

NO YES

3.

Are the fuel supply, tank, pump, ventilation See Fuel System. and emission control systems in correct working order or the fuel contaminated?

NO

If

starting at

to

crank

battery in good state

-

problem is not diagnosed repeat tests,

the cranking speed fast enough

-

necessary also

-

there combustion in any cylinder?

-

problem is not diagnosed repeat tests,

Charge the battery.

See ETM B1

1.

Charge the battery. Continue. starting at 1.

See Ignition system tests. See ETM A1 1. Continue. incorrectly adjusted?

See Fuel System or Emission

Control. systems in order?

2.

see

of

ETM

charge?

B1

(120

rpm)?

ENGINE RUNNING PROBLEMS

but

will

immediately Engine stalls Engine misfires/hesitation

Multiport fuel injection. See ETM A1.

1.

Check brake vacuum connections.

Brakes.

If

problem is not diagnosed continue.

2.

Are

HT

leads correctly routed and clipped?

NO

-

YES

-

3.

Is

fuel supply, tank, pump, ventilation and emission control systems in correct working order or the fuel contaminated?

NO

-

If

problem is not diagnosed repeat tests,

Engine lacks power/poor performance

Is

accelerator pedal travel restricted or cable

YES

-

NO

-

2. Is

the Ignition and Multiport Fuel Injection

NO

-

YES

-

See Electrical.

Continue.

See Fuel System.

Check thickness of carpets. Continue.

See

ETM

A1

Continue.

not

but

idle

stops

See

3.

Is

fuel supply, emission control systems in correct working order or the fuel contaminated? NO

-

YES

-

4.

Is

oil pressure high?

YES

-

NO

-

tank,

See Fuel System or Emission Control. Suspect valves held open by hydraulic tappets due oil pressure. See Engine oil pressure test.

Remove oil filter and cooler

adaptor and check pressure

relief valve strainer gauze for blockage and that the relief valve is not stuck closed. See Lubrication system.

Carry out cylinder compression tests head gaskets and valves. Cylinder compression test.

pump, ventilation and

to

determine condition of

to

high

See

ENGINE

5.

Are cylinder compressions satisfactory? Engine backfires into NO

-

YES

-

If problem is not diagnosed: Continue.

6.

Are the brakes binding?

YES

-

NO

-

Engine backfires into exhaust system

1.

Are there any leaking joints/connections or Emission control. holes in the exhaust system? YES

YES

-

NO

-

2.

Is

distributor

correct firing order and routed correctly? valves etc. See Cylinder

NO

-

YES

-

3.

Is

air fuel ratio

NO

-

YES

-

For overhaul, see Remove and overhaul cylinder heads. Check brake vacuum correct?

see

connections,

Investigate cause of binding.

See Brakes. see Continue. Check brake vacuum

Brakes.

1. Is the Distributor, HT connections and routing

NO

-

YES

2.

Is

air fuel ratio correct?

NO

-

See Exhaust system.

Continue. 3. Are cylinder compressions satisfactory?

NO

-

fitted

See Electrical. compression test.

Continue. For overhaul, see Remove and overhaul

correct?

Check multiport fuel injection, starting at see ETM A1. Check brake vacuum connections, Check the crank case and fuel tank ventilation system. See Emission control. Continue.

correctly,

see

HT

leads in check for leaking gaskets

cylinder heads.

If

problem is not diagnosed: repeat tests

Brakes.

inlet

system

See Electrical.

Continue.

Check multiport fuel injection,

ETM

A1.

connections, Check the crank case and fuel tank ventilation system. See

Continue.

Carry out compression test

1.

see

Brakes.

to

4.

Are cylinder compressions satisfactory?

NO

-

If

problem is

starting at

Carry out compression test to

check for leaking gaskets valves etc. See Cylinder compression test.

For overhaul,

overhaul cylinder heads.

not

diagnosed: repeat tests

1.

see

Remove and

ENGINE

Remove

2.

3.

4. Disconnect battery. 16. Disconnect hose from reservoir

5.

6.

7.

8.

9.

10. Remove ram housing.

11. Remove air flow sensor. re-assembly and disconnect plugs from

12.

13.

14.

REMOVAL

Park vehicle on level ground and apply park

1.

brake. Depressurize fuel system, see Depressurise

fuel system.

Remove bonnet, see CHASSIS AND BODY. Remove radiator/oil coolers.

Place an absorbent cloth around fuel feed of fluid reservoir

hose at fuel rail and release compression nut. fluid.

Remove feed hose from rail, seal end of pipes

with masking tape

Release fuel return hose clamp and remove openings with masking tape

hose from pressure regulator, seal both openings with masking tape

of dirt. Remove vacuum hose from rear of regulator.

Disconnect throttle cable from bracket. Disconnect leads from coil.

Remove air cleaner assembly. Remove alternator, See alternator. Release air conditioning compressor from its PIace to one side clear of engine assembly.

mounting and lay discharge air conditioning system.

to

prevent ingress of dirt. steering box hose. Seal hose and pump

to

prevent ingress chassis or steering box.

to

one side. DO NOT

NOTE: Release bolts securing compressor mounting bracket to engine and remove bracket

to enable temporary lifting eye ETC

fitted.

fixing points with suitable bolts of equivalent size, pitch and thread. Leave lifting eye attached until engine is reinstalled in vehicle.

22.

Secure lifting eye to mounting bracket

15.

Place drain tray underneath vehicle.

steering pump. Secure hose end above level

to

avoid unnecessary

17.

Disconnect power steering pump

of

dirt. Wipe away any fluid spillage from

18.

Disconnect fuel temperature and coolant temperature sensor multi

Identify injectors.

21.

Manoeuvre harness from behind fuel rails and

Remove cooler pipes

23.

Remove engine mounting fixings on both sides of cylinder block.

24. Fit lifting chains shown in illustration

each

two

clamps securing gearbox oil

to

engine block.

-

plugs.

injector multi-plug

to

engine lifting eyes as

RR1780E.

5964

to

prevent ingress

to

power

loss

power

be

of

for

RRl780E

1.

L/H

2.

R/H

3.

R/H

Front chain 356mm total overall length.

Front chain 330mm Rear chain 457mm total overall length

total

overall length.

ENGINE

NOTE: All chain dimensions are measured from

end of lifting hook to end of last link in chain.

25. Fit chain lifting eye to a suitable engine hoist. Raise hoist high enough to enable engine 44. Lower engine into engine compartment. mountings to be removed, and withdraw Ensure all components are clear of engine rubber mountings. assembly.

26. Lower hoist until engine rests securely on 45. Lower engine into position. Locate primary engine mounting brackets. Remove lifting pinion into clutch. Engage bell housing chains and hoist. dowels.

27. Disconnect two heater hoses located on top of right hand rocker cover. 47. Remove jack and lower hoist until engine

28. Remove ground strap from rear of left hand

cylinder head. DO NOT remove from retaining 48. Fit top two bell housing securing bolts. clip. Tighten to 40 Nm.

29. Remove all electrical harnesses from retaining clips at rear of engine.

30. Remove transmission breather pipes from bolts, and tighten to 40 Nm. retaining clip on rear lifting eye. Remove top two bolts securing bell housing to bolts to 9 Nm.

31. cylinder block. Raise front of vehicle, lower vehicle on to axle manifold.

32. stands. 52. Refit all harnesses, ground straps breather

Remove bell housing bottom cover. Remove pipes and hoses at rear of engine.

33. gasket from bell housing face. 53. Raise engine and refit engine mounting Remove nuts securing exhaust downpipes to rubbers, tighten nuts to 20 Nm.

34. manifolds, remove heat shield from right hand side downpipe.

35. Remove electrical leads from starter motor electrical plugs and harnesses are fitted in solenoid. Disconnect multi sensor on side of sump, if fitted.

36. Remove remaining bell housing to cylinder block bolts.

37. Remove starter motor ground strap from chassis.

38. Remove stands and lower vehicle.

39. Position hydraulic trolley jack under bell housing to support gearbox when engine and gearbox are separated.

40. Fit lifting chains to engine. Carefully raise hoist a little, ease engine and gearbox apart, steady engine on hoist.

41. Ensure no components remain that will Prevent engine being removed.

42. Slowly compartment. Move engine away from vehicle and place on a suitable engine stand.

raise

engine clear of

-

plug from oil level correct locations.

engine

Refit

43. Fit lifting chains hoist.

46. Fit two bolts and partially tighten. rests securely

49. Fit remaining bell housing to cylinder block

50. Fit new gasket and refit bottom cover, tighten

51. Fit new exhaust flange gaskets, fit exhaust to

54. Remove temporary lifting eye ETC 5964 and reverse instructions 1 to 23, ensuring that all

to

engine. Raise engine using

on

engine mounting brackets.

ENGINE

ENGINE - DISMANTLE AND OVERHAUL

Remove engine from vehicle, see engine removal and clean exterior. For safe and efficient working secure engine to an approved engine stand. Drain

engine oil into a suitable container.

Remove intake manifold

1.

Release hose clamp at water pump manifolds and gaskets.

2.

Detach retaining clips from top of injectors.

3.

Remove four bolts securing fuel rail to manifold.

4.

Withdraw fuel rail and injectors.

5.

Evenly loosen and remove twelve bolts securing intake manifold to cylinder heads.

6.

Lift intake manifold from cylinder heads.

7.

Remove surplus coolant, remove gasket

clamp bolts, remove clamps.

8.

Lift

off

gasket and seals.

Remove exhaust manifolds

1.

Bend back lock tabs, remove eight bolts securing each manifold, and withdraw

Remove water pump

1.

Remove fifteen bolts, pump and joint washer.

NOTE: The water pump is not serviceable. II event

of

failure, fit a new water pump assembly.

RR1794E

n

ENGINE

REMOVE AND OVERHAUL

ROCKER

AND VALVE GEAR

1. Remove spark plug leads

from

and retaining clips. Release four screws and

lift

off

rocker covers.

2.

Remove four rocker shaft retaining

lift

off

assembly.

SHAFTS Dismantle rocker shafts

5.

Remove split pin from one end

of

rocker shaft.

spark plugs 6. Withdraw following components and retain in

bolts

and

correct sequence for re

7.

A

plain washer.

8.

A

wave washer.

9.

Rocker arms.

-

assembly:

10. Brackets.

11. Springs.

12. Examine each component for wear, in particular rockers and shafts. Discard weak or broken springs.

3. Withdraw pushrods and retain in sequence removed.

4. Remove hydraulic tappets. Retain with their

If

respective pushrods.

a tappet cannot be removed leave in position until camshaft is removed.

ST787M

Inspect tappets and

pushrods

13. Hydraulic tappet: inspect inner and outer surfaces of body for blow holes and scoring. Fit a new hydraulic tappet scored or grooved,

if

body is roughly

or

has a blow hole extending through wall in a position to permit oil leakage from lower chamber.

just

14. The prominent wear pattern end of body should not

above lower

be

considered a

defect unless it is definitely grooved or scored.

of

It is caused by side thrust

I

S

body while tappet

moving vertically in its

cam against

bore.

15. Inspect cam contact surface of tappets. Fit new tappets

surface

is

excessively worn

if

damaged.

16.

A

hydraulic tappet body that has been rotating

will have a round wear pattern.

will

tappet body

have a square wear pattern

A

non-rotatlng

with a very slight depression near centre.

5

or

17.

Tappets MUST rotate, a circular wear condition

is

normal. Tappets with this wear

pattern can be refitted provided there are no

other defects.

18.

If

a tappet is not rotating check camshaft lobes for wear. Fit new tappet ensuring it rotates freely in cylinder block.

RR750M

19.

Fit a new hydraulic tappet

if

area of pushrod

contact is rough or damaged.

20.

Fit a new pushrod

or damaged ball end

if

it is bent or has a rough

or

seat.

22.

Fit new split pin to one end of rocker shaft. Slide a plain washer over the long end

23.

shaft to contact the split pin.

24.

Fit a wave washer to contact plain washer.

RR2937M

25.

Early type rocker arms are angled. They must be fitted angle away from each other as shown.

26.

On offset and must be fitted as shown.

27.

Early and late rocker arms are interchangeable provided complete set changed.

ENGINE

of

so

that valve end

later type rocker arms the valve end

of

rocker arms

the

I

is

S

Assemble rocker shafts

21.

Assemble rocker shafts with identification

groove at one o'clock position with push rod

end of rockers to the right.

RR2900M

CAUTION:

If

incorrectly assembled

and rockers are fitted

to

rocker shafts

will

to

engine, oil

be restricted.

shafts

supply

RR2899M

Assemble rocker arms, brackets and springs

28.

to rocker shaft.

29.

Compress the springs, fit wave washer, plain washer and split pin

30.

Fit locating bolts through brackets. Place assemblies

to

one side.

to

end

of

rocker shaft.

ENGINE

REMOVE AND OVERHAUL CYLINDER HEADS

1. Evenly loosen fourteen cylinder head bolts, 7. Clean valves. reversing tightening order. 8. Clean valve guide bores.

2.

Mark heads

3.

Lift

off

Dismantle cylinder heads

4.

Remove spark plugs. 12. Correct angle for seat is 46° ± 1/4 and seat

5.

Using valve spring compressor 18G 106A suitable alternative, remove valves, springs, retain valve stem seals.

LH

and

RH

for reassembly.

cylinder heads, discard gaskets.

in

sequence for refitting. Discard inlet

or

a witness towards outer edge.

6.

Clean combustion chambers using a brush.

9.

Regrind

10. If a valve has to be ground to a knife obtain a true seat, fit a new valve.

11. Correct angle for valve seating face 1/4.

or

fit new valves as necessary.

soft

wire

-

edge to

is

45°

±

ST793M

13. Check valve guides and fit replacements as necessary. Using valve guide remover

from

274401, drive out old guides seat face of cylinder head.

valve spring

ENGINE

Examine and fit new valve seats

Check valve seats for wear, pits and burning.

15.

Fit new inserts Remove old seat inserts by grinding them until

16. thin enough

17.

Heat cylinder head evenly

65°C.

Press new insert into recess in cylinder head.

18.

NOTE: Service valve seat inserts are available in mm larger on outside diameter to ensure interference fit.

if

necessary.

to

be cracked and pried

to

two

over-sizes

0.25

out.

approximately

and

0.50

Fit new valve guides

NOTE:

Service valve guides are

0,025

mm larger on outside diameter than original equipment ensure interference fit.

14.

Lubricate new valve guide and place in

position.

A.

Using guide drift LRT-12-038 partially drive guide into cylinder head.

B.

Remove drift LRT-12-038 and place distance

-12-

piece LRT

515 over valve guide. Drift guide into head until distance piece contacts spring seat.

C.

Alternatively drift guide into cylinder head until

it

protrudes 19

in

head.

mm

above valve spring recess

to

19. Using service valve seats

20.

Nominal seat width is 1,5

2,O

mm it should be reduced

width by the use

to

tool

46°

MS621

±1/4,

of

20° and

mm.

70°

21. The inlet valve seat diameter: and exhaust valve seat is

31,510

if

necessary, cut

If

seat exceeds

to

the specified

cutters.

'A'

is

37,03

mm.

mm

RR2355M

ST797M

ENGINE

22.

Ensure cutter blades are correctly fitted cutter head with angled end downwards, facing work, as illustrated. Check that cutter blades are adjusted middle

be

Use light pressure and remove only minimum material necessary.

of

blade contacts area

cut. Use key provided in hand set MS76.

of

blade

so

material

to

that

to

Reclaiming cylinder head threads

ST1024M

23.

Coat valve seat with a small quantity 'engineers' blue, revolve a properly ground

A

valve against seat.

should appear round valve. not more than 12 mm it can

lapping. insert)

24. Alternatively, insert a strip of cellophane between valve and seat, hold valve down by

slowly

stem, drag, seal in at least eight places. Lapping

a small open spot.

Re-Assemble valves

25.

Before fitting valves and springs, check height

of

each valve above head. Measure height of stem above valve spring seat surface, holding head firmly against seat. This dimension must not exceed valve or grind end

26. Lubricate valve stems. Fit new inlet valve stem seals and springs. Fit caps, compress springs using LRT

pull out cellophane.

is

satisfactory in that spot. Repeat

to

47.63

-12-

continuous fine line Holes B - These eight holes may

If

there is a gap

be

corrected by Tap No. 6 CBB

If

there is a

-

in

will

correct

cylinder head

mm.

If

of

valve stem.

034 and

necessary

fit

collets.

fit

a new

of

Damaged or stripped threads in cylinder head can be salvaged by fitting Helicoils as follows:

Holes

A - These three holes may be drilled

x

dia. Tap No. 6 CPB or 6CS UNC

dia. x 0.812

Holes C dia Tap No. 6 CPB or 6CS UNC 1.5D insert).

Holes D - These four holes may be drilled 0.261 in dia Tap No.

UNC

Holes dia Tap No. 6 CPB or 6CS UNC 1.5D insert).

0.937

1.5D

.

x

0.937

x

0.675

1.5D

E

x

0.937

+

0.040

insert).

+

0.040

-

These four holes may

+

0.040

+

0.040

4

CPB or 4CS x 0.625 in (min) deep

insert).

-

These six holes may

+

0.040

0.749

in

deep. Tapped with Helicoil

x

0.875

in

deep. Tapped with Helicoil

in

(min) deep

in

deep. Tapped with Helicoil

x

in

deep. Tapped with Helicoil

in

deep. Tapped with Helicoil

x

0.875

in (min) deep

be

0.875

in

be

in (min) deep

drilled

(min) deep

drilled

(3/8

0.3906

(3/8

0.3906

UNC

1.5D

0.3906

0.3906 (3/8

in

(3/8

(1/4

in

RR751M

ENGINE

REMOVE AND OVERHAUL FLYWHEEL

1.

Remove retaining bolts and withdraw flywheel

from crankshaft.

NOTE:

Right-hand cylinder head illustrated.

F Exhaust manifold face

G Intake manifold face

H Front face I Rear face

J Front of engine

REMOVE FLEXIBLE DRIVE PLATE AND RING GEAR ASSEMBLY

NOTE:

identification line to enable re original

1.

2.

Scribe each component

with

-

assembly

an refaced provided minimum thickness does

in

position.

Remove four retaining bolts. broken teeth. Renew as follows:

Withdraw clamp ring, flexible drive plate, hub aligner and ring gear assembly.

3. Remove six socket head bolts securing crankshaft adaptor plate and shim to crankshaft flange.

4.

Withdraw crankshaft adaptor plate and shim.

5.

Inspect ring gear assembly for distortion,

cracks, chipped or badly gear

is

in

poor

condition

worn

teeth.

fit

a new assembly.

If

ring

2.

Examine flywheel clutch face for cracks,

scores and overheating. The flywheel can be not go below 39.93 mm

(1.572

in). Remove

three dowels before machining.

3.

Examine ring gear for worn, chipped and

3

RR1806E

ST803M

4.

Drill a

10

mm diameter hole axially between roots of any tooth and inner diameter starter ring sufficiently deep

NOT

DO

allow drill

to

enter flywheel.

to

weaken ring.

of

ENGINE

5.

Secure flywheel in a vice using place a cloth over flywheel

from flying fragments.

soft

jaws and

to

protect operator

REMOVE TIMING GEAR

PUMP

COVER

AND WATER

WARNING: against flying fragments when splitting ring gear.

Place a chisel as shown, strike it sharply

6.

split starter ring gear.

Take adequate precautions

to

1.

Place an oil drip-tray beneath timing cover, remove oil filter element.

2.

Remove crankshaft pulley bolt and special washer, withdraw pulley.

7. Heat new ring gear uniformly to between

°

C and 175°C,

170

temperature.

8.

Place flywheel, clutch side down, on flat

surface. timing cover.

9.

Locate heated starter ring gear

flywheel, towards flywheel flange.

chamfered both sides, it can way round.

10. Press starter ring gear until ring contracts sufficiently to grip flywheel.

11.

Allow flywheel to HASTEN cooling occur.

12.

Fit new clutch assembly location dowels to

flywheel.

with

DO

NOT

EXCEED higher

3.

Remove

in

position on

chamfered inner diameter cover complete with

If

starter ring gear is

be

fitted

either

firmly

cool

gradually.

in

any way, distortion may

against flange

DO

NOT

4.

Remove timing cover bolts and withdraw

two

bolts securing sump

oil

pump.

to

bottom

of

ST804M

Fit new timing cover oil seal

5.

Remove seven drive screws and withdraw

mud shield and oil seal.

6.

Position gear cover with front face uppermost and underside supported across oil seal housing bore on a suitable wooden block.

7.

Enter

oil

seal, lip side leading, into housing

bore.

8.

Press in approximately

9.

Fit mud shield and securing screws.

oil

seal until plain face

1,5

mm below gear cover face.

ENGINE

is

REMOVE AND OVERHAUL OIL PUMP

DISTRIBUTOR

1.

Release single nut securing distributor clamp.

2.

Remove clamp, withdraw distributor.

3.

If

necessary overhaul distributor.

REMOVE

REMOVE ENGINE PLATE

1.

Remove both oil cooler pipes.

2.

Mark position

3.

Remove centre fixing and withdraw adaptor plate.

Refit

4.

Reverse the removal procedure, lining location marks to ensure pipe runs are

correct. Ensure the pipes and centre fixing are tightened to the specified torque.

OIL

COOLER

of

adaptor plateloil pump cover.

ADAPTOR

up

the

1.

Remove bolts from oil pump cover.

2.

Withdraw oil pump cover.

3.

Lift

off

cover and remove gasket.

4.

Withdraw oil pump gears.

Dismantle pump

5.

Unscrew plug from pressure relief valve.

6.

Remove sealing washer from plug.

7.

Withdraw spnng from relief valve.

8.

Withdraw pressure relief valve.

ENGINE

Assemble pump

17. Insert relief valve spring.

18.

Locate sealing washer on relief valve plug.

19.

Fit relief valve plug, tighten

to

40 - 47 Nm.

20. Fully pack oil pump gear housing with Petroleum Jelly.

No

other grease is suitable.

21. Fit oil pump gears ensuring that Petroleum

Jelly

is

forced into every cavity between teeth

of gears.

ST809M

Examine pump

9.

Check

oil

pump gears for wear/scoring.

10. Fit oil pump gears and shaft into front cover.

11. Place a straight edge across gears.

12. Check clearance between straight edge and front cover.

lf

less than

0.05

mm, check front

cover gear recess for wear.

11

IMPORTANT: Unless pump is fully packed with Petroleum Jelly

it

may not prime itself

when engine is started.

22. Place new gasket on oil pump cover.

in

23. Locate oil pump cover

position.

24. Fit special fixing bolts and tighten to 13 Nm.

ST810M

13.

Check oil pressure relief valve for wear/scoring.

14. Check sides of relief valve

spring

signs of collapse.

15.

Clean wire screen filter for relief valve.

16.

Check relief valve is an easy slide perceptible side movement in its bore.

for wear or

fit

with no

ENGINE

REMOVE

TIMING CHAIN SPROCKET AND

CAMSHAFT

1.

Remove retaining bolt and washer. Withdraw

distributor drive gear and spacer.

RR1797E

2.

Withdraw sprocket complete with timing chain.

ST813M

Examine components

4. Visually examine all parts for wear. Fit a new camshaft

if

bearing journals and cams show

signs of wear, pits, scores and overheating.

5.

Examine links and pins

of

timing chain for

wear. Compare its condition with a new chain.

Inspect teeth

of

sprockets,

if

necessary

new sprocket.

6.

Measure camshaft journals for overall wear, ovality and taper. Diameters of journals are as

follows,

from front

of

shaft:

fit

a

3.

Withdraw camshaft, taking particular care not

to

damage bearings in cylinder block.

Number 1 journal 45,4 to 45,3 mm Number 2 journal 44,6 to 44,5 mm Number 3 journal 43,84 to 43,81 mm Number 4 journal 43,07 to 43,05 mm Number 5 journal 42.31 to 42,29 mm

7.

To

check camshaft for straightness rest two

1

end journals i.e. numbers

and 5 on 'V'

blocks and mount a dial gauge on centre

'journal. Rotate shatt and note reading.

is

more than 0.05 mm fit a new camshaft.

out

If

run

ENGINE

REMOVE AND OVERHAUL CONNECTING RODS Overhaul AND PISTONS

NOTE: Retain connecting rods, caps and bearing

1.

Withdraw retaining bolts and remove sump.

2. Remove sump oil strainer.

3. Remove connecting rod caps, retain in sequence for reassembly.

4.

Screw guide bolts LRT-12-041 onto

connecting rods.

shells piston rings over is to

rod to ensure that original assembly is maintained.

in

be

7.

Withdraw piston pin, using tool LRT-12-013:

sets,

refitted, mark it relative to its connecting

in

correct sequence. Remove

crown

of

piston.

If

same piston

5.

Push connecting rod and piston assembly up g. cylinder bore, withdraw connecting rod and piston assemblies in h. sequence with respective caps.

6.

Remove guide bolts LRT-12-041 from

connecting rod.

it

from

top.

Retain screw.

a. Clamp hexagon body

in vice.

b. Position large nut flush with end of

centre screw.

C.

d. Locate piston adaptor LRT

e.

f.

i.

j.

k.

Push screw forward until nut contacts thrust race.

with its long spigot inside bore hexagon body. Fit remover/replacer bush of LRT

-12-

013 on centre screw with

flanged end away from piston pin.

Screw stopnut about half-way onto smaller threaded end of centre screw, leaving a gap between nut and remover/replacer bush.

Lock Check

correctly

Push connecting-rod to right expose end

be located in end of adaptor 'd'. Screw large nut up to thrust race.

Hold

until piston pin has been withdrawn

from

stop-nut securely with

that remover/replacer bush is

positioned

lock

piston. Dismantle

'A'

of

piston pin, which must

screw and turn large nut

of

LRT-12-013

of 3 mm

in

bore of piston.

tool.

-12-

(1/8

013

of

in)

lock

to

ST816M

ST777M

Original pistons

Remove carbon deposits, particularly from ring

8.

grooves. Examine pistons for signs or excessive wear, refer to new pistons for method new pistons

of

checking running clearance.

if

New pistons

necessary.

of

damage

Fit

9.

Check cylinder bore dimension at right angles

40

to

50

to piston pin

mm from

top.

NOTE: Pistons are available

in

service standard

size pistons supplied 0.0254 mm oversize.

0.25

Oversize pistons are

mm and 0.50 mm oversize. When fitting new service standard size pistons to a cylinder block, check for correct piston to bore clearance, honing bore

if

necessary. Bottom of piston skirt/bore clearance should

NOTE:

must

be

0.018

to 0.033 mm.

Piston and cylinder block temperature

be

same to ensure accurate measurement. When reboring cylinder block, crankshaft main bearing caps must

be

fitted and tightened to

70

Nm.

ST817M

10.

ST818M

ENGINE

Check piston dimension at right angles to

of

piston pin, at bottom

skirt.

14.

Temporarily fit compression rings

15.

The ring marked marking uppermost into second groove. The chrome ring

either way round.

16.

Check compression ring clearance in piston groove. Clearance limits:

‘TOP’

fits

top groove and can be fitted

must be fitted with

0.05

to

0.10 mm.

piston.

11.

The piston dimension must be 0.018 to 0.033 mm smaller than cylinder.

12.

If

new piston rings are reboring, deglaze cylinder walls with a hone without increasing bore diameter, to provide a

-

hatch finish. After honing, thoroughly

cross clean piston bores foreign matter.

13. Check compression ring in applicable cylinder, 17. Fit expander ring into bottom groove making held square to bore with piston. Gap limits:

0.44

to

0.56

mm. Use a fine-cut flat file to

if

required. Select a new piston

does

not

NOTE:

rings.

increase gap

if

gap exceeds limit.

ring

Gapping

to

be fitted without

to

remove all traces

apply to

oil

of

control

Fit piston rings

sure that ends butt and do not overlap.

18.

Fit

two

ring rails to bottom groove, one above

and one below expander ring.

19. Fit second compression ring

’TOP’

groove, either way round.

uppermost. Fit chrome ring into top

with

marking

19

ST819M

ST821M

Examine connecting rods

20. Check alignment of connecting rod.

21. Check connecting rod small end, piston pin must be a press fit.

Check crankshaft bearings

22. Locate bearing upper shell into the connecting rod.

23.

Locate connecting rod and bearing

crankshaft journal.

NOTE: Domed shape boss on connecting rod must face towards front of engine

right hand bank of cylinders and towards

rear

on

left hand bank.

24.

When both connecting rods are fitted, bosses 30. Remove connecting rod cap and shell.

will

face inwards towards each other.

onto

its

on

31.

Using scale printed on Plastigauge packet, measure flattened Plastigauge at its widest point.

32.

The graduation most closely corresponding width clearance.

33. Correct bearing clearance with new or overhauled components is 0.015

If

34.

bearing

35.

If

assembly

36. Wipe

NOT scrape

of

Plastigauge indicates bearing

a bearing has been

if

clearance exceeds

a new bearing is being fitted, use selective

to

obtain correct clearance.

off

Plastigauge with an oily rag.

it

off.

ENGINE

in

service,

0.08

to

mm.

0.055

fit

a new

to

mm.

DO

ST822M

25.

Place a piece of Plastigauge (P61) across

centre of lower half of crankshaft journal. 37.

26.

Locate bearing lower shell into connecting rod

cap.

27. Locate cap and shell onto connecting rod.

NOTE: Note that rib be on same side as domed shape connecting rod.

28. Secure connecting rod cap. Tighten

29.

Do

not rotate crankshaft while Plastigauge

in use.

on

edge

of

cap must

boss

to

NOTE: It is important that connecting rods, caps and bearing shells sets, and in correct sequence.

Assembling pistons to connecting rods

Using tool LRT connecting rod as follows:

on

a.

b.

Clamp hexagon body of LRT-12-013

in a vice, with adaptor LRT positioned as instruction 7d. Remove large nut of LRT-12-013 and push the centre screw approximately

50

Nm. exposed.

is

C.

Slide parallel guide sleeve, grooved

end last, onto centre screw and up shoulder.

be

retained

-12-

013 refit each piston

mm into body until shoulder is

to

-12-

in

its

014

to

ENGINE

d.

e.

f.

g. Fit remover/replacer bush LRT-12-015

h. Screw stop nut onto centre screw and

I.

Lubricate piston pin and bores connecting rod and piston with represents minimum load for an graphited oil (Molykote 2). lubricate ball race and centre screw

of

LRT-12-013.

Fit connecting rod and piston together

onto tool, with markings aligned fitting original pair, with connecting remover/replacer bush is 4mm rod around sleeve up

Fit piston pin into piston bore, up

connecting rod. with its flanged end towards piston

pin.

adjust nut float nut securely with screw. Slide assembly back into hexagon body and screw large nut up to thrust

race.

to

obtain an

'A'

on whole assembly, and lock

to

groove.

0.8

mm end

of

Also

if

to

j.

k.

Set a torque spanner acceptable interference

in

connecting rod.

Using torque spanner and socket large nut, and holding lock screw, pull

piston pin in until flange

to

16

Nm. This

fit

of

piston

on

of

'B'

of

from face not be allowed

CAUTION: If torque spanner has

not reached

throughout pull, fit of piston pin to connecting rod

and necessitates fitting new components. The large nut and

centre screw well oiled.

piston. This flange must

to

contact piston.

at

least

is

not acceptable

of

tool must be kept

16

Nm.

k

ST778M

h

38.

Remove tool and check that piston moves freely on piston pin and that no damage has occurred during pressing.

REMOVE AND OVERHAUL CRANKSHAFT

1.

Remove main bearing caps and lower bearing shells. of journal

Retain

until

in pairs and mark

it

is decided

if

with

bearing shells

are to be refitted.

2.

Lift

out

crankshaft and rear oil seal.

number

ST824M

ENGINE

Inspect and overhaul crankshaft

3.

To check for straightness, place crankshaft on

-

blocks at numbers one and five main undersize, as shown in following chart.

vee bearing journals. Using a dial indicator, check run-out at centre faces on either side of centre main journal

4.

main bearing journal. must be

5.

Total run-out at each journal should not 14. Main bearing journal diameter, see following

0.08

exceed

6.

If

crankshaft is bent it is not suitable for

regrinding and should

7.

Check each crankshaft journal for ovality. ovality exceeds

journal, regrind or

8.

Crankshaft main and connecting rod bearings are available in following undersizes:

mm.

be

0.040

mm around crankshaft

fit

a

new crankshaft.

renewed.

If

9.

The centre main bearing shell, which controls crankshaft thrust,

in

thickness when more than 0.25 mm

10.

When a crankshaft is to be reground, thrust

machined

dimensions in charts Main bearing journal size Thrust face width Standard Standard

0.25 mm undersize Standard

0.50

mm undersize

11.

For example:

bearing, 0.125 mm must be machined

each thrust face

correct radius.

Crankshaft dimensions

12. Radius for all journals except rear main bearing

13. Radius for rear main bearing journal is

mm. chart.

15. Thrust face width, and connecting rod journal

diameter,

is

1.90

see

has thrust faces increased

in accordance

that

follow.

0.25

mm oversize

If

fitting a

of

to

2.28

following chart.

0.50

mm undersize

centre journal, maintaining

mm.

with

off

3.04

ST826M

0.25mm

0.50mm

RR1793E

13

Crankshaft dimensions-millimetre

ENGINE

Cranks Grade

Standard 58.400

0.254

0.508 U/S 57.892 Check main bearing clearance 26. Graduation most closely corresponding

haft

U/S

16. Remove oil seals from cylinder block and rear clearance. main bearing cap. 27. Correct bearing clearance with new

17. Locate upper main bearing shells (with oil overhauled components

hole and oil grooves) into cylinder block. 28.

18. Locate flanged upper centre main bearing select a suitable bearing to give required

shell. clearance.

19. Place crankshaft in position on bearings. 29. Wipe

20. Place a piece crankshaft main bearing journals.

21. Locate lower shells into main bearing caps.

Diameter

58.146-58.158

of

Plastigauge across centre

'12'

-

58.412

-

57.904

Width

26.975

27.229

of

'13'

-

27.026 50.800-50.812

-

27.026 50.546-50.558

-

27.280 50.292-50.304

width

If

correct clearance is not obtained initially,

off

scrape

30. Maintain bearing shells and caps in sets, the correct sequence.

ASSEMBLING ENGINE FIT CRANKSHAFT AND MAIN BEARINGS

1. Locate upper main bearing shells (with oil holes and grooves)

2. Locate the flanged upper centre main bearing shell.

3.

Lubricate crankshaft main bearing journals and bearing shells with clean engine

lower crankshaft into position.

it

Diameter

of

Plastigauge indicates bearing

Plastigauge with an oily rag.

'1

4'

is

0.023 to 0.065

off.

in

cylinder block.

Do

oil

mm.

NOT

and

to

or

in

ST828M

22. Fit numbers one to four main bearing caps and shells, tighten

23. Fit rear main bearing cap and shell and

tighten

rotate while Plastigauge is in use.

24. Remove main bearing caps and shells.

25. Using scale printed on Plastigauge packet, measure flattened Plastigauge at widest point.

to

90 Nm.

to

70 Nm.

Do

not allow crankshaft

to

ST830M

4.

Lubricate lower main bearing shells and

to

numbers one

four main bearing caps and guide outer surface completely to ensure

shells only, leave the fixing bolts finger

5.

Fit

cross shaped side seals

side of rear main bearing cap.

to

grooves each assembly.

Do

seals, they must protrude

not cut side Position oil seal,

1.5

fit

-

tight. that

NOTE:

oil

Lubricant coating must cover seal

seal lip is not turned back during

mm engine, on to seal guide. Seal outside

approximately above bearing cap parting face. diameter must

6.

Apply Hylomar SQ32M jointing compound rearmost half of rear main bearing cap parting

if

face

or,

preferred, to equivalent area on recess formed in cap and block until

cylinder block as illustrated.

Lubricate bearing half and bearing cap side Withdraw seal guide.

7.

to

12. Push oil seal fully and squarely by hand into contacts machined step

seals with clean engine oil.

8.

Carefully fit bearing cap assembly.

9.

Do

not tighten fixings, but ensure that cap is fully home and squarely seated on cylinder block.

lipped

be

clean and dry.

in

side towards the

it

recess.

CAUTION:

Do not handle oil seal lip, check it is not damaged and ensure that outside diameter remains clean and dry.

10.

Position seal guide LRT-12-010 on crankshaft

flange.

11. Ensure that oil seal guide and crankshaft journal are scrupulously clean. Coat seal

guide and oil seal journal with clean engine oil.

13. Tighten cap bolts

to

one

bearing

four bearings

90

Nm.

14. Check crankshaft end

CAUTION:

to

correct torque, numbers

70

Nm, rear main

-

float, 0.10

to

0.20 mm.

Do not exceed 1,000 engine

rev/min for 15 seconds when first starting

engine, otherwise crankshaft rear oil seal

will be damaged.

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

REAR AXLE AND FINAL DRIVE

PROPELLER SHAFTS

REAR SUSPENSION

STEERING AND FRONT SUSPENSION

POWER ASSISTED STEERING

BRAKES

ELECTRICAL EQUIPMENT

PRECAUTIONS AGAINST DAMAGE PREPARATION

DISMANTLING

INSPECTION - GENERAL

METRIC NUT IDENTIFlCATlON

KEYS AND KEYWAYS

TAB WASHERS

NUTS UNIFIED THREAD IDENTIFICATION

Nuts

LOCKING WIRE

SCREW THREADS

CAPACITIES

WORKSHOP MAINTENANCE SCHEDULES

CALIFORNIA

SPECIAL OPERATING CONDITIONS

ADDITIONAL DAILY OR WEEKLY ATTENTION DEPENDING ON OPERATING CONDITIONS:

MONTHLY

LUBRlCATlON

RENEW MAIN AND TRANSFER GEARBOX OILS DRAIN AND RENEW LT230T TRANSFER

DRAIN AND REFILL LT77S MAIN GEARBOX

LUBRICATE PROPELLER SHAFTS

GENERAL MAINTENANCE AND ADJUSTMENT

CHANGING THE HYDRAULIC BRAKE FLUID

AXLE BREATHERS