1993 Land Rover Defender 90 Workshop Manual LDAWMEN93US – PDF DOWNLOAD
FILE DETAILS:
1993 Land Rover Defender 90 Workshop Manual LDAWMEN93US – PDF DOWNLOAD
Language : English
Pages : 492
Downloadable : Yes
File Type : PDF
Size: 16.5 MB
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
1993 Land Rover Defender 90 Workshop Manual LDAWMEN93US – PDF DOWNLOAD
Car Park 0
Library 0
Defender Workshop Manual Table of Contents 1
Introduction 11
WARNINGS and CAUTlONS 11
REFERENCES 11
DIMENSIONS 11
REPAIRS AND REPLACEMENTS 11
FUEL HANDLING PRECAUTIONS 11
HOT FUEL HANDLING PRECAUTIONS 12
FUEL TRANSFER 12
FUEL TANK REMOVAL 12
RECOMMENDED SEALANTS 12
POISONOUS AND DANGEROUS SUBSTANCES 13
Engine oils 13
Health protection precautions 13
Asbestos 13
Synthetic rubber 13
DISPOSING OF USED OILS AND FLUIDS 13
Environmental protection precaution 13
ACCESSORIES AND CONVERSIONS 14
SPECIFICATION 14
Special Service Tools 15
ABBREVIATIONS AND SYMBOLS 16
LOCATION OF VEHICLE IDENTlFlCATlON AND UNIT NUMBERS 17
VEHICLE IDENTtFlCATlON NUMBER (VIN) 17
Key to Vehicle Identification Number Plate 17
MAIN GEARBOX LT77 18
TRANSFER GEARBOX LT230T 18
FRONT AXLE 18
REAR AXLE 18
04 – GENERAL SPECIFICATION DATA 19
ENGINE 3 9 V8 19
Crankshaft 19
Main bearings 19
Connecting rods 19
Connecting rods 19
Big-end bearings 19
Piston pins 19
Pistons 20
Piston rings 20
Camshaft 20
Tappets 20
Valves 20
Lubrication 20
TRANSMISSION 21
Transfer gearbox 21
Rear Axle – One Ten only 21
Rear Axle – Ninety only 21
Front Axle 21
Rear Axle – One Ten only 21
Rear Axle – Ninety only 21
Front Axle 21
PROPELLER SHAFTS 21
SUSPENSION 21
BRAKES 22
Foot brake 22
STEERING 22
Power steering box 22
Steering pump 22
ELECTRICAL EQUIPMENT 23
Battery 23
Alternator 23
Starter motor 23
Distributor & MFI system 23
Wiper motor 23
Fuses 23
Coil 24
REPLACEMENT BULBS AND UNITS 24
VEHICLE DIMENSIONS 110 25
VEHICLE DIMENSIONS 90 25
VEHICLE WEIGHTS AND PAYLOAD 25
WHEELS AND TIRES 26
TIRE PRESSURES 26
05 – ENGINE TUNING DATA 27
ENGINE 3 9 V8 27
06 – TORQUE WRENCH SETTINGS 28
ENGINE 28
FUEL LINES 28
CLUTCH 28
MAIN GEARBOX (FIVE-SPEED) LT77S 29
TRANSFER GEARBOX LT230T 30
FRONT AXLE 30
REAR AXLE AND FINAL DRIVE 31
PROPELLER SHAFTS 31
REAR SUSPENSION 31
STEERING AND FRONT SUSPENSION 31
POWER ASSISTED STEERING 32
BRAKES 32
ELECTRICAL EQUIPMENT 32
AIR CONDITIONING 32
07 – GENERAL FITTING INSTRUCTIONS 33
PRECAUTIONS AGAINST DAMAGE 33
SAFETY PRECAUTIONS 33
PREPARATION 33
DISMANTLING 33
INSPECTION – GENERAL 34
BALL AND ROLLER BEARINGS 34
OIL SEALS 34
JOINTS AND JOINT FACES 35
FLEXIBLE HYDRAULIC PIPES, HOSES 35
METRIC BOLT IDENTIFICATION 36
METRIC NUT IDENTIFlCATlON 36
HYDRAULIC FlTTlNGS – Metrication 36
KEYS AND KEYWAYS 37
TAB WASHERS 37
SPLIT PINS 37
NUTS 38
LOCKING WIRE 38
SCREW THREADS 38
UNIFIED THREAD IDENTIFICATION 38
09 – RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES 39
RECOMMENDED LUBRICANTS AND FLUIDS 39
Anti-Freeze 40
CAPACITIES 41
10 – MAINTENANCE 42
WORKSHOP MAINTENANCE SCHEDULES 42
ALL NORTH AMERICAN MODELS 43
CALIFORNIA 44
SPECIAL OPERATING CONDITIONS 49
ADDITIONAL DAILY O R WEEKLY ATTENTION DEPENDING ON OPERATING CONDITIONS: 49
MONTHLY 49
LUBRlCATlON 50
RENEW ENGINE OIL 50
RENEW OIL FILTER 50
RENEW MAIN AND TRANSFER GEARBOX OILS 51
DRAIN AND REFILL LT77S MAIN GEARBOX 51
DRAIN AND RENEW LT230T TRANSFER GEARBOX OIL 51
RENEW SWIVEL PIN HOUSING OIL RENEW FRONT AND REAR AXLE OIL 52
LUBRICATE PROPELLER SHAFTS 52
RENEW FRONT AND REAR AXLE OIL 52
GENERAL MAINTENANCE AND ADJUSTMENT 53
EXAMINE AND RENEW DISC BRAKE FRICTION PADS 53
CHANGING THE HYDRAULIC BRAKE FLUID 54
AXLE BREATHERS 54
CHECK STEERING BALL JOINTS 54
CHECK FRONT WHEEL ALIGNMENT 55
ADJUST REAR BRAKES DEFENDER 110 ONLY 55
ADJUST TRANSMISSION BRAKE (Handbrake) 56
FILTERS 57
AIR CLEANER ELEMENT 57
AIR CLEANER DUMP VALVE 57
FUEL FILTER 57
Charcoal canister Defender 110 58
Charcoal canister Defender 90 58
POSITIVE CRANKCASE VENTlLATION INTAKE FILTER 58
CLEAN PLENUM CHAMBER VENTILATION PASSAGEWAY 59
CLEAN POSITIVE CRANKCASE VENTILATION BREATHER FILTER 59
GENERAL MAINTENANCE AND ADJUSTMENTS 60
CHECK/ADJUST OPERATION OF ALL WASHERS AND TOP-UP RESERVOIR 60
IGNITION 60
Spark plugs 60
Fitting H T leads 60
CLEAN AND LUBRICATE V8 ENGINE ELECTRONIC DISTRIBUTOR every 40,000 km (24,000 miles) 61
AIR CONDITIONING SYSTEM DEFENDER 110 61
CHECK BRAKE FLUID RESERVOIR 62
CHECK CLUTCH FLUID RESERVOIR 62
POWER STEERING FLUID RESERVOIR 63
CHECK COOLING SYSTEM COOLANT 63
BATTERY 63
Check Specific Gravity 63
Check and Top-Up Electrolyte Level 64
Battery terminals 64
RENEW BRAKE SERVO FILTER 64
THROTTLE PEDAL ADJUSTMENT 65
DRIVE BELT TENSIONING 65
FAN/WATER PUMP DRIVE BELT ADJUSTMENT 65
AIR CONDITIONING COMPRESSOR DRIVE BELT DEFENDER 110 66
ADJUSTMENT 66
ALTERNATOR AND POWER STEERING PUMP DRIVE BELT ADJUSTMENT 66
POWER STEERING PUMP DRIVE BELT 66
ALTERNATOR DRIVE BELT 67
RESET EMISSION MAINTENANCE REMINDER 67
12 – ENGINE 69
DESCRIPTION 69
Lubrication system 72
Distributor/oil pump drive and timing chain lubrication 73
Filtered oil 73
Unfiltered oil 73
Hydraulic tappets 74
Operation 74
ENGINE FAULT DIAGNOSIS 75
ENGINE OIL PRESSURE TEST 75
CYLINDER COMPRESSION – TEST 75
ENGINE NOISES 76
ENGINE STARTING PROBLEMS 77
ENGINE RUNNING PROBLEMS 77
ENGINE REMOVAL 79
ENGINE – DISMANTLE AND OVERHAUL 81
Remove intake manifold 81
Remove exhaust manifolds 81
Remove water pump 81
REMOVE AND OVERHAUL ROCKER SHAFTS AND VALVE GEAR 82
Dismantle rocker shafts 82
Inspect tappets and pushrods 82
Assemble rocker shafts 83
REMOVE AND OVERHAUL CYLINDER HEADS 84
Dismantle cylinder heads 84
Fit new valve guides 85
Examine and fit new valve seats 85
Re-Assemble valves to cylinder head 86
Reclaiming cylinder head threads 86
REMOVE FLEXIBLE DRIVE PLATE AND RING GEAR ASSEMBLY 87
REMOVE AND OVERHAUL FLYWHEEL 87
REMOVE TIMING GEAR COVER AND WATER PUMP 88
Fit new timing cover oil seal 89
DISTRIBUTOR REMOVE 89
REMOVE ENGINE OIL COOLER ADAPTOR PLATE 89
REMOVE AND OVERHAUL OIL PUMP 89
Dismantle pump 89
Examine pump 90
Assemble pump 90
REMOVE TIMING CHAIN SPROCKET AND CAMSHAFT 91
Examine components 91
REMOVE AND OVERHAUL CONNECTING RODS AND PISTONS 92
Overhaul 92
Original pistons 93
New pistons 93
Fit piston rings 94
Examine connecting rods 95
Check crankshaft bearings 95
Assembling pistons to connecting rods 95
REMOVE AND OVERHAUL CRANKSHAFT 97
Inspect and overhaul crankshaft 98
Crankshaft dimensions 98
Crankshaft dimensions-millimetre 99
Check main bearing clearance 99
ASSEMBLING ENGINE 99
FIT CRANKSHAFT AND MAIN BEARINGS 99
FIT CONNECTING RODS AND PISTONS 101
FIT CAMSHAFT TIMING CHAIN AND SPROCKET 102
FIT CYLINDER HEADS 103
FIT TAPPETS, PUSH RODS AND ROCKER ASSEMBLIES 104
FIT INTAKE MANIFOLD 105
FIT TIMING COVER AND CRANKSHAFT PULLEY 105
FIT WATER PUMP 106
FIT SUMP 106
TEST AND FIT THERMOSTAT 106
FIT DISTRIBUTOR 107
FIT ROCKER COVERS 108
FIT ENGINE OIL FILTER 109
FIT EXHAUST MANIFOLD 109
MISCELLANEOUS AND NON-STANDARD ITEMS 109
CYLINDER HEAD GASKETS – RENEW 110
CYLINDER HEADS – RENEW 110
ROCKER COVER – RIGHT HAND – RENEW 111
ROCKER COVER – LEFT HAND – RENEW 111
ROCKER SHAFT RENEW 112
HYDRAULIC TAPPETS RENEW 113
CRANKSHAFT PULLEY ASSEMBLY 113
FRONT COVER OIL SEAL – RENEW 113
FRONT COVER GASKET 114
Refit 114
TIMING CHAIN AND CHAINWHEELS 115
Remove 115
Refit 115
FLYWHEEL 115
Remove 115
Refit 115
CRANKSHAFT REAR OIL SEAL 115
Service Tools 117
17 – EMISSION CONTROL 120
EMISSION CONTROL 120
Crankcase ventilation system 120
EVAPORATIVE EMISSION CONTROL 121
Fuel tank evaporative control 121
Evaporative purge system Operation 121
Fuel tank evaporative control system 122
Operation 122
FUEL EXPANSION TANK 122
DEFENDER 110 122
Remove 122
Refit 122
DEFENDER 90 123
Remove 123
Refit 123
HEATEDOXYGENSENSOR 123
CHARCOAL CANISTER DEFENDER 110 123
CHARCOAL CANISTER – PURGE VALVE DEFENDER 110 124
CHARCOAL CANISTER DEFENDER 90 124
POSITIVE CRANKCASE VENTILATION AIR INTAKE FILTER 125
POSITIVE CRANKCASE VENTILATION BREATHER FILTER 125
EMISSION LABEL 126
Defender 110 Emissions label – 1993 Model Year 126
Defender 90 Emissions label – 1994 Model Year 126
19 – FUEL SYSTEM 127
DIAGNOSTIC EQUIPMENT 127
IGNITION 127
LUCAS MFI DIAGNOSTIC EQUIPMENT Complete kit Land Rover Part No RTC 6834 127
MEMORY CARDS 127
HOT WIRE MULTIPORT FUEL INJECTION 128
Description 128
Electronic control module – ECM 128
Injectors 128
Engine coolant temperature sensor 128
Engine fuel temperature sensor 128
Idle air control valve 128
Heated oxygen sensors 128
Fuel pressure regulator 128
Fuel pump 128
Mass air flow sensor 129
Throttle position sensor 129
Condenser fans 129
Vehicle speed sensor 129
Inertia fuel shut off switch 129
Relay modules 129
ENGINE TUNING 130
ECM – MFI circuit diagnosis 130
Preliminary checks 130
MULTI METER CHECKS 130
Testing 130
MULTI PORT FUEL INJECTION (MFI) CIRCUIT DIAGRAM ST3358M 131
BASE IDLE SPEED SETTlNG 132
Equipment required 132
Checking procedure 132
Adjusting base idle speed 132
FUEL PRESSURE CHECK 133
INJECTOR TESTS 133
Leak Test 133
Fuel Delivery Test 133
REMOVING AIR CLEANER 134
REMOVING MASS AIR FLOW SENSOR 134
REMOVING THROTTLE POSITION SENSOR 135
REMOVING IDLE AIR CONTROL VALVE 135
REMOVING VEHICLE SPEED SENSOR 136
REMOVING FUEL INJECTION-RELAY MODULES 136
REMOVING INERTIA FUEL SHUT-OFF SWITCH 137
REMOVlNG ENGINE FUEL TEMPERATURE SENSOR 137
REMOVING ENGINE COOLANT TEMPERATURE SENSOR 137
DEPRESSURISING FUEL SYSTEM 138
REMOVING FUEL PRESSURE REGULATOR 138
REMOVING FUEL RAIL-INJECTORS R/H AND L/H 139
REMOVING PLENUM CHAMBER 140
KEY 141
To Remove 140
Removing throttle lever assembly 140
inspect and overhaul throttle lever assembly 142
Inspect and overhaul throttle disc 143
Assemble throttle levers and bracket 144
To Refit 144
REMOVING RAM HOUSING 145
REMOVING INTAKE MANIFOLD 145
REMOVING FUEL FILTER 146
REMOVING FUEL TANK AND FUEL PUMP DEFENDER 110 147
FUEL PUMP/SENDER UNIT 149
REMOVING ACCELERATOR CABLE 149
REMOVING ACCELERATOR PEDAL 150
26 – COOLING SYSTEM 151
COOLING SYSTEM 151
Engine Protection 151
DRAIN AND FILL COOLING SYSTEM 151
REMOVING WATER PUMP 152
REMOVING THERMOSTAT 152
REMOVING RADIATOR 154
COOLING SYSTEM FAULT DIAGNOSIS 155
30- MANIFOLDS AND EXHAUST 157
EXHAUST SYSTEM COMPLETE 157
EXHAUST SYSTEM 158
EXHAUST MANIFOLD 158
INTAKE MANIFOLD 158
ASSEMBLY RENEWAL CLUTCH 159
SPECIAL TOOLS 159
33 – CLUTCH 159
ASSEMBLY RENEWAL CLUTCH 159
SPECIAL TOOLS 159
CLUTCH FAULT DIAGNOSIS 160
CLUTCH DRAGS 160
OVERHAUL RELEASE BEARING ASSEMBLY 161
OVERHAUL MASTER CYLINDER – All models 161
OVERHAUL SLAVE CYLlNDER 163
CLUTCH PEDAL AND MASTER CYLINDER ADJUSTMENT 164
BLEED CLUTCH HYDRAULIC SYSTEM 164
RENEW CLUTCH SLAVE CYLINDER 165
RENEW CLUTCH MASTER CYLINDER 165
Left hand drive vehicles 165
37 – LT77S MANUAL GEARBOX 167
REMOVE LT77S MANUAL GEARBOX AND LT230 TRANSFER BOX 167
MATERIAL AND WELDING SPECIFICATION 168
Separating the transfer box from gearbox 168
Fitting main gearbox and transfer box to engine 169
DISMANTLE 170
Bell housing 170
GEAR SELECTOR HOUSING 170
EXTENSION HOUSING 170
MAINSHAFT AND LAYSHAFT FIFTH GEARS 171
REVERSE SHAFT, LAYSHAFT AND MAINSHAFT 174
DISMANTLE MAINSHAFT 175
GEARBOX CASINGS AND OIL PUMP 177
Front cover 177
Centre plate 177
Extension case 177
GEAR SELECTOR HOUSING – MAIN GEARBOX 181
Reverse gear plunger assembly 182
Transfer gear housing 182
GEAR SELECTOR HOUSING – TRANSFER GEARBOX 183
SYNCHROMESH ASSEMBLIES 184
Third-fourth and fifth gear synchromesh 184
First-second synchromesh 185
CHECKING BAULK RING CLEARANCES 186
INPUT SHAFT 187
MAINSHAFT 187
MAINSHAFT GEAR END FLOAT CHECKS 188
Second gear end-float 188
Third gear end-float 188
First gear bush end-float 188
First-second synchromesh assembly 189
Selective first gear bush 189
Check first gear to bush end-float 189
ASSEMBLING MAINSHAFT 190
First gear assembly 190
Third-fourth synchomesh assembly 191
LAYSHAFT 192
REVERSE GEAR AND SHAFT 192
SELECTORS 193
Assembling selectors 194
ASSEMBLING GEARBOX SHAFTS TO CENTRE PLATE 194
Fitting gears to centre plate 194
FITTING GEARBOX CASING 196
FITTING FIFTH GEAR 197
EXTENSION CASE 200
INPUT-MAINSHAFT BEARING ADJUSTMENT 201
LAYSHAFT BEARING ADJUSTMENT 201
GEAR LEVER AND REMOTE HOUSING ASSEMBLY 202
Bias spring adjustment 203
BELL HOUSING 204
GEARS AND SHAFTS 204
GEARBOX CASING 206
DATA 207
TORQUE VALUES 207
SERVICE TOOLS 208
LOCALLY MANUFACTURED TOOLS 210
41 – LT230T TRANSFER GEARBOX 212
REMOVE LT230T TRANSFER GEARBOX FROM THE LT77S GEARBOX 212
OVERHAUL 214
TRANSFER GEARBOX DATA 215
TORQUE WRENCH SETTING 216
Differential and Output Drive Assembly 218
Intermediate Gear and Power Take Off Assembly 219
Rear Output Drive and Transmission Brake Assembly 220
DISMANTLE 221
Transmission brake removal 221
Bottom cover removal 221
Intermediate shaft and gear cluster removal 221
Input gear removal 222
High/low cross – shaft housing removal 223
Front output housing removal 223
Centre differential removal 223
Rear output housing removal 223
Transfer case, dismantle and overhaul 224
Transfer case overhaul – reassembling 224
Rear output housing dismantle and overhaul 225
Reassembling rear output housing 226
Re-assembling centre differential 230
Centre differential rear bearing track 231
Rear output housing – refit 232
Centre differential unit refit 232
Front output housing dismantle and overhaul 233
Re-assembling front output housing 234
Adjusting front differential bearing pre – load 235
Differential lock finger housing – dismantle and overhaul 237
Re-assembling 237
High/low cross – shaft housing overhaul 238
Input gear overhaul – dismantle and overhaul 238
Re-assembling input gear assembly 239
Checking input gear bearing pre – load 240
Intermediate gear assembly overhaul 240
Intermediate gear reassembly 241
Adjusting intermediate gear torque – to – turn 242
Power take – off cover – reassemble 242
Bottom cover – reassemble 242
Differential lock switch adjustment 243
Transmission brake drum – re-assemble 243
Adjusting intermediate gear torque – to – turn 244
Power take – off cover – reassemble 244
Bottom cover – reassemble 244
Differential lock switch adjustment 245
Transmission brake drum – re-assemble 245
47 – PROPELLER SHAFTS 246
OVERHAUL PROPELLER SHAFTS 246
Dismantle 246
Assemble 247
51 – REAR AXLE AND FINAL DRIVE 248
REAR HUBS 248
REMOVE AND OVERHAUL 248
Remove 248
Overhaul hub 248
Assemble 248
Fitting inner oil seal 248
Fitting outer oil seal 248
Fitting outer oil seal 248
Fitting hub to stub axle 248
KEY TO REAR HUB COMPONENTS 250
OVERHAUL REAR AXLE DIFFERENTIAL ASSEMBLY (SALISBURY) ONE TEN MODELS 251
DISMANTLE 251
Using axle compressor GKN 131 252
Dismantle differential 252
Remove final drive pinion 253
INSPECTION 254
ASSEMBLE 254
Assemble differential unit 254
Differential bearing adjustment 254
Fit drive pinion 255
Drive pinion markings 256
Drive pinion adjustment 256
Differential backlash checks 258
Torque resistance initial setting figures 259
OVERHAUL REAR AXLE DIFFERENTIAL ASSEMBLY DEFENDER 90 259
REAR DISCS 260
Remove and refit 260
Removing 260
Refitting 260
Disc Reclamation 260
REMOVE AND OVERHAUL REAR HUBS MODELS WITH REAR DISC BRAKES 260
Remove 260
Assemble 261
Fitting new oil seal-inner 261
Fitting outer oil seal 262
Fitting hub to stub axle 262
KEY TO REAR HUB COMPONENTS 264
54 – OVERHAUL FRONT HUB ASSEMBLY 265
DISMANTLE 265
KEY TO HUB ASSEMBLY 265
Assemble 266
OVERHAUL STUB AXLE, AXLE SHAFT, CONSTANT VELOCITY JOINT AND SWIVEL ASSEMBLY 267
Remove stub axle, axle shaft and constant velocity joint 267
Remove constant velocity joint from axle shaft 268
Dismantle the constant velocity joint 268
Fit constant velocity joint to axle 269
Renew stub axle intermediate oil seal and bush 269
Remove swivel pin housing 269
Remove swivel pin bearing housing 269
Overhaul swivel pin bearing housing 269
Fit swivel pin bearing housing to axle 269
Fit swivel pin housing 269
KEY TO DRIVE SHAFT AND SWIVEL ASSEMBLY 270
Fit drive shaft and stub axle 271
FRONT AXLE DIFFERENTIAL 274
Adjust crown wheel and pinion backlash 275
DISMANTLE 276
INSPECTION 279
ASSEMBLE 280
Differential carrier and crown wheel 280
Fitting pinion bearing tracks 282
Pinion height setting 282
Pinion bearing pre-load adjustment 285
Fitting pinion oil seal 285
DATA 287
TORQUE FIGURES 287
57 – STEERING 288
REMOVE AND OVERHAUL STEERING COLUMN 288
Remove the collapsible shaft 288
Remove the steering wheel 288
Remove the instrument panel 288
Remove the steering column switches 288
Remove the brake perdal box 289
Overhaul the steering column 290
Fitting steering column 291
Fit steering column lock switch 291
Fit steering column switch assembly 292
Fit instrument panel and nacelle 292
Fit the steering wheel 292
Fit collapsible steering shaft 293
TORQUE FIGURES 293
POWER STEERING BOX OVERHAUL 294
Adwest Lightweight 294
KEY TO LIGHTWEIGHT POWER STEERING BOX 296
Dismantle 297
Steering box casing 299
Steering box casing 299
Sector shaft and cover assembly 299
Valve and worm assembly 300
Ball bearing and cage assemblies 301
Rack and piston 301
Rack thrust pad and adjuster 302
ASSEMBLE 302
Fitting input shaft oil seal 302
Fitting sector shaft seal 303
Fitting valve and worm assembly 303
Torque peak check 307
Fitting steering box to vehicle and testing 307
POWER STEERING SYSTEM – Adwest Test Lightweight box 308
Bleed 308
Procedure 308
TEST EQUIPMENT 309
ADJUST POWER STEERING BOX – Adwest Lightweight box 309
PIPE CONNECTIONS TO STEERING BOX 310
STEERING BOX SECTOR SHAFT SEAL – renew with steering box fitted to vehicle 310
Fitting new seals 311
POWER ASSISTED STEERING PUMP – OVERHAUL 312
Assemble 313
Power assisted steering pump connections 314
KEY TO PAS PUMP 315
POWER STEERING FAULT DIAGNOSIS 316
OVERHAUL DROP ARM BALL JOINT 317
Dismantle 317
Assemble 318
TRACK ROD AND DRAGLINK 319
FRONT WHEEL ALIGNMENT – Check and adjust 319
Checking 319
Adjusting 319
64 – SUSPENSION 320
OVERHAUL REAR SUSPENSION 320
Remove the lower links 320
Renew the bushes 320
Remove upper links 320
Renew pivot bracket ball joint 320
Assemble upper links and ball joints 320
Renew anti-roll bar bushes and ball joints 320
LEVELLING UNIT 321
Functional check 321
LAND ROVER COIL SPRING SPECIFICATION 321
REMOVE LEVELLING UNIT 322
Renew levelling unit ball joints 322
Fit levelling unit 322
SPRINGS AND SHOCK ABSORBERS 322
Remove rear springs 322
Fit rear springs 322
Remove shock absorbers 322
Test shock absorbers 322
Fit shock absorbers 322
Land Rover 110 Rear Suspension 324
PAN HARD ROD 325
Remove 325
Refit 326
RADIUS ARM 325
FRONT SHOCK ABSORBER 326
Remove 326
Refit 326
FRONT ROAD SPRING 327
Remove 327
Refit 327
BUMP STOP 327
Remove 327
Refit 327
ANTI-ROLL BAR ASSEMBLY 328
KEY 328
ANTI-ROLL BAR FRONT 328
Remove 328
Refit 328
ANTI-ROLL BAR BALL JOINT LINKS 329
Remove 329
Refit 329
70 – BRAKING SYSTEM 330
BRAKES 330
DESCRIPTION 330
REMOVE AND OVERHAUL BRAKE CALIPERS 331
Remove caliper 331
Do not separate the caliper halves 333
Assemble rim-half pistons 333
Mounting-half pistons 333
Fit calipers and pads to vehicle 333
OVERHAUL REAR BRAKES – 110 models 334
DISMANTLING 334
Dismantle and overhaul wheel cylinder 334
Assembling rear brake 334
OVERHAUL TRANSMISSION BRAKE 335
DISMANTLING 335
KEY TO TRANSMISSION BRAKE 335
Remove and overhaul expander assembly 336
Assemble expander assembly 336
Remove and overhaul adjuster assembly 336
Assemble adjuster assembly 336
ASSEMBLE 336
BLEEDING THE BRAKES 337
Primed System 337
Unprimed System 337
RENEWING FRONT BRAKE DISCS 338
Removing 338
Fitting 339
OVERHAUL MASTER CYLINDER – Lucas Girling – Type 25 4 mm AS/AS 340
Dismantling master cylinder 340
KEY TO MASTER CYLINDER 341
Assembling master cylinder 342
Renewing secondary plunger seals 343
RENEW BRAKE MASTER CYLINDER – Lucas Girling type 25,4 mm AS/AS 344
Removing 344
Fitting new master cylinder 344
RENEW ‘G’ VALVE – where fitted 345
Removing 345
Fitting 345
RENEW SERVO NON RETURN VALVE 345
Remove 345
Fitting new valve 345
RENEW BRAKE SERVO – L S C 80 346
Removing 346
Fitting servo 346
FAULT DIAGNOSIS 347
76 – CHASSIS AND BODY 348
CHASSIS ALIGNMENT AND SQUARENESS 348
Frame alignment 348
DEFENDER 110 CHASSIS ALIGNMENT DIMENSIONS 350
DEFENDER 90 CHASSIS ALIGNMENT DIMENSIONS 352
DOORS DEFENDER 110 353
Right-hand rear side door lock mechanism 353
Right-Hand front door lock mechanism 353
REMOVING THE DOOR TRIM – DEFENDER 110 354
Fitting door trim 354
REMOVING WINDOW REGULATORS DEFENDER 110 – Rear side door 355
Remove 355
Fitting regulator 355
REMOVING EXTERIOR HANDLE DEFENDER 110 – rear side door 356
Remove 356
Fitting handle 356
REMOVING DOOR LOCKING BUTTON DEFENDER 110 – Rear side door 356
Remove 356
Fitting locking button 356
REMOVING REMOTE CONTROL LEVER DEFENDER 110 – Rear side door 357
Remove 357
Fitting control lever 357
REMOVING DOOR LATCH ASSEMBLY DEFENDER 110 – Rear side door 357
Remove 357
Fitting the latch 358
REMOVING DOOR GLASS DEFENDER 110 Rear side door 358
Fitting glass 359
REMOVING MOUNTING PANEL DEFENDER 110 Front doors 360
Remove 360
Fitting mounting panel 360
REMOVING DOOR LOCKING BUTTON DEFENDER 110 – Front doors 360
Remove 360
Fitting locking button 361
REMOVING WINDOW REGULATOR DEFENDER 110 – Front doors 361
Remove 361
Fitting regulator 361
REMOVING REMOTE CONTROL LEVER DEFENDER 110 – Front doors 361
Remove 361
Fitting remote control lever 362
REMOVING EXTERIOR DOOR HANDLE DEFENDER 110 – Front doors 362
Remove 362
Fitting the handle 362
REMOVING THE DOOR LATCH ASSEMBLY DEFENDER 110 – Front doors 363
Remove 363
Fitting latch assembly 363
REMOVING GLASS DEFENDER 110 – Front doors 364
Remove 364
Fitting glass 364
REMOVING LOCKING BARREL DEFENDER 110 – Front doors 365
Remove 365
Refit the lock barrel 366
REMOVING REAR SIDE WINDOW TRIM DEFENDER 110 366
Remove 366
To refit 367
REMOVING ‘B’ POST TRIM DEFENDER 110 368
Remove 368
Refit 368
REMOVING REAR QUARTER LIGHT TRIM Defender 110 369
Remove 369
Refit 369
REMOVING GRAB HANDLES DEFENDER 110 369
Remove 369
Refit 369
DOOR LOCK, REAR DOOR DEFENDER 110 370
FRONT AND REAR DOORS DEFENDER 90 370
Removal, Defender 110 370
Barrel removal 370
Barrel refitting 370
Refitting 370
Removal, Defender 90 370
Refitting 370
Striker adjustment 371
Dovetail adjustment 371
80 – HEATING AND VENTILATION 372
HEATER/FAN UNIT Remove, Overhaul and refit 372
REMOVE FROM VEHICLE 372
OVERHAUL 372
Fan Motor Assembly 372
Heater Matrix 373
Resistor Unit 373
REFIT TO VEHICLE 373
82 – AIR CONDlTlONlNG 374
AIR CONDITIONING DEFENDER 110 374
General Service Information 374
INTRODUCTION 374
Servicing equipment 374
SERVICING MATERIALS 374
PRECAUTIONS IN HANDLING REFRIGERANT 374
PRECAUTIONS IN HANDLING REFRIGERANT LINES 374
PERIODIC MAINTENANCE 375
Condenser 375
Compressor 375
Receiver/Drier 375
Evaporator 375
Service valves 375
Stem type 375
Schrader Type 377
Schrader service valve 377
Valve Core Remover 377
AIR CONDITONING CIRCUIT DIAGRAM 378
Key to Circuit Diagram 378
AIR CONDITIONING BLOWER MOTOR AND CONTROL SYSTEM DIAGNOSIS 379
Refrigeration System Fault Diagnosis 380
COMPRESSOR CLUTCH DIAGNOSIS 382
MECHANICAL AIR CONDITIONER BLOWER MOTOR AND CONTROL SYSTEM DIAGNOSIS 383
CHARGING AND TESTING EQUIPMENT 384
Connecting the gauge set 384
Fitting 384
Removing 385
AIR CONDITIONING SYSTEM OPERATIONS 385
Depressurising 385
Evacuating 386
Sweeping 387
Charging 388
Leak test 388
Pressure test 389
Test 389
COMPRESSOR 390
Remove 390
Refit 390
COMPRESSOR DRIVE BELT 390
Adjust 390
CONDENSER FAN MOTORS 390
Removal 390
CONDENSER AND RECEIVER/DRIER 391
Removal 391
Condenser removal only 391
Receiver/drier removal 391
Refitting 392
EVAPORATOR 392
Removal 392
Heater matrix and blower motor only 392
Evaporator matrix and expansion valve only 392
Evaporator unit 393
Blower motor unit removal only 395
Heater/Evaporator matrices removal only 395
Expansion valve removal 395
Refitting 395
RESISTOR BLOCK 395
Removal 395
Refitting 395
86 – ELECTRICAL EQUIPMENT 396
ELECTRICAL PRECAUTIONS 396
Polarity 396
High voltage circuits 396
Connectors and harness 396
Battery disconnecting 396
Battery charging 396
GENERAL PRECAUTIONS 396
DISTRIBUTOR – 35DLM8 397
Remove and refit 397
Removing 397
Refitting 397
35 DLM8 Distributor components 398
DISTRIBUTOR – LUCAS 35DLM8 399
Overhaul 399
DISTRIBUTOR COVER 399
ROTOR ARM 399
INSULATION COVER (Flash shield) 399
VACUUM UNIT 399
AMPLIFIER MODULE 399
PICK-UP AND BASE PLATE ASSEMBLY 399
RE-ASSEMBLY 399
LUBRICATION 399
Apply clean engine oil: 399
Apply Chevron SR1 (or equivalent) grease 399
FITTING PICK-UP AND BASE PLATE ASSEMBLY 399
REFlTTlNG RELUCTOR 399
PICK-UP AIR GAP ADJUSTMENT 400
AMPLIFIER MODULE 400
IGNITION TIMING ADJUSTMENT 400
Static ignition timing 400
Dynamic ignition timing 400
Equipment required 400
Calibrated Tachometer Stroboscopic lamp 400
ELECTRONIC IGNITION – PRELIMINARY CHECKS 401
PICK-UP AIR GAP 401
TEST 1: 401
Check HT Sparking 401
TEST 2: 401
L T Voltage 401
EXPECTED READINGS 401
KEY 401
TEST 3: 401
TEST 4: 402
Pick-Up Coil Resistance 402
TEST 5: 402
Coil HT Sparking 402
TEST 6: 402
Rotor Arm 402
TEST 7: 403
Visual and HT Cable Checks 403
ALTERNATOR – TYPE A127 404
BATTERY 404
STARTER MOTOR – Type M78R 405
Overhaul 405
Dismantling 405
Inspecting 406
Solenoid 406
Brush gear 406
Armature 407
Drive assembly 407
Bearings 407
Reassembly 407
HEADLAMPS 407
To remove or renew bulb or light unit 407
To remove or renew headlamp assembly 408
Assemble and refit 409
SIDE, TAIL AND FLASHER LAMPS 410
Renew bulbs and lamps 410
Refitting lamp and bulbs 410
REAR NUMBER PLATE LAMP 410
Remove and renew bulbs 410
Refitting lamp and bulbs 410
REAR LAMPS 411
REVERSE LIGHT SWITCH 411
Remove and refit 411
WARNING LAMPS 412
INSTRUMENT ILLUMINATION 412
WIPER MOTOR – OVERHAUL 413
DISMANTLE 413
INSPECTION AND TEST 413
ASSEMBLE 414
KEY TO WIPER MOTOR COMPONENTS 414
RENEW WIPER MOTOR AND DRIVE RACK 415
Removing wiper motor 415
Fitting wiper motor 416
RENEW WINDSCREEN WIPER ARMS 416
Remove 416
Fitting new arm 416
RENEW WINDSCREEN WIPER WHEELBOXES 417
Remove 417
Wiper motor and drive rack 417
Fitting wheelboxes 417
ELECTRICAL SYSTEMS 418
ENGINE HARNESS 419
AIR CONDITIONING FANS HARNESS ASSEMBLY DEFENDER 110 ONLY 419
CHASSIS HARNESS 420
MAIN HARNESS 421
MFI HARNESS 423
RADIO HARNESS 424
ENGINE HARNESS CONNECTORS ST3409M 425
AIR CONDITIONING HARNESS CONNECTORS ST3411M DEFENDER 110 ONLY 427
MULTIPORT FUEL INJECTION HARNESS CONNECTORS ST3410M 429
MAIN CABLE ASSEMBLY CONNECTORS UNDER BONNET ST3407M 431
MAIN CABLE CONNECTORS VEHICLE INTERIOR ST3407M 431
CHASSIS AND RADIO HARNESS CONNECTORS ST3408M 433
LOCATION O F RELAYS, TIMERS AND CONTROL UNITS DEFENDER 110 (ST3362M) 435
LOCATION OF RELAYS, TIMERS AND CONTROL UNITS DEFENDER 90 (ST3442M) 436
CIRCUIT DIAGRAMS 437
FUSES 437
DASH FUSE BOX SCHEMATIC DEFENDER 110 ST3385M 438
DASH FUSE BOX SCHEMATIC DEFENDER 90 ST3443 439
MULTIPORT FUEL INJECTION (MFI) CIRCUIT DEFENDER 110 (ST3358M) 440
MULTI PORT FUEL INJECTION (MFl) CIRCUIT DEFENDER 90 (ST3445M) 441
AIR CONDITIONING CIRCUIT DEFENDER 110 (ST3361M) 442
STARTING SYSTEM CIRCUIT DEFENDER 110 (ST3394M) 443
STARTING SYSTEM CIRCUIT DEFENDER 90 (ST3446M) 444
CHARGING AND TACHOMETER CIRCUIT DEFENDER 110 (ST3384M) 445
CHARGING AND TACHOMETER CIRCUIT DEFENDER 110 (ST3447M) 446
HAZARD FLASHER CIRCUIT DEFENDER 110 (ST3386M) 447
HAZARD FLASHER CIRCUIT DEFENDER 90 (ST3448M) 448
DIMMING MIRROR CIRCUIT DEFENDER 110 (ST3391M) 449
REVERSE AND STOP LAMP CIRCUIT DEFENDER 90 AND 110 (ST3387M) 450
HEATED FRONT SCREEN CIRCUIT DEFENDER 110 (ST3383) 451
REAR WINDOW DEMIST CIRCUIT DEFENDER 110 (ST3381M) 452
HORN, CLOCK, INTERIOR LIGHT AND AUXILIARY CIRCUITS DEFENDER 110 (ST3395M) 453
HORN, CLOCK, INTERIOR LIGHT AND AUXILIARY CIRCUITS DEFENDER 90 (ST3449M) 454
RADIO SYSTEM CIRCUIT DEFENDER 110 (ST3401) 455
RADIO SYSTEM CIRCUIT DEFENDER 90 (ST3450M) 456
LIGHTING CIRCUIT DEFENDER 110 (ST3388M) 457
LIGHTING CIRCUIT DEFENDER 90 (ST3388M) 458
FRONT WASH/WIPE SYSTEM CIRCUIT DEFENDER 90 AND 110 (ST3402M) 459
REAR WASH/WIPE CIRCUIT DEFENDER 110 (ST3382M) 460
WARNING LlGHTS/CHECK CIRCUIT DEFENDER 90 AND 110 (ST3393M) 461
AUDIBLE WARNING SYSTEM CIRCUIT DEFENDER 110 (ST3397M) 462
AUDIBLE WARNING SYSTEM CIRCUIT DEFENDER 90 (ST3397M) 463
COOLANT TEMPERATURE GAUGE CIRCUIT DEFENDER 110 (ST3389M) 464
COOLANT TEMPERATURE GAUGE CIRCUIT DEFENDER 90 (ST3451M) 465
FUEL TANK LEVEL INDICATOR CIRCUIT DEFENDER 110 (ST3400M) 466
FUEL TANK LEVEL INDICATOR CIRCUIT DEFENDER 90 (ST3452M) 466
BATTERY CONDITION INDICATOR CIRCUIT DEFENDER 110 (ST3399M) 467
AUXILIARY FEED CIRCUIT DEFENDER 90 (ST3453) 467
CENTRE DIFFERENTIAL LOCKED CIRCUIT DEFENDER 90 AND 110 (ST3398M) 468
CIGAR LIGHTER CIRCUIT DEFENDER 90 AND 110 (ST3392M) 468
SPLIT CHARGE AND VOLTAGE SENSITIVE SWITCH CIRCUIT DEFENDER 110 (ST3403M) 469
TRAILER CIRCUIT DEFENDER 110 (ST3390M) 470
Supplement Table of Contents 471
76 – BODY 473
REAR SEAT CUSHION 473
REAR SEAT SQUAB 473
REAR SEAT BELTS 474
SIDE TRIM PANEL 475
INTERIOR ROLL-OVER BAR 476
REAR END TRIM PANEL 477
CUBBY BOX 478
REAR GRAB HANDLE 478
REAR END LINING 479
REAR SPEAKER PANEL 479
REAR HEADLINING 480
REAR DOOR TRIM CASING 481
SUN ROOF 482
FRONT HEADLINING 483
INTERIOR REAR VIEW MIRROR 484
SUN VISORS 484
FRONT SEAT BELTS 485
EXTERIOR ROLL-OVER BAR 486
REAR TOW BAR 487
86 – ELECTRICAL 488
REAR WIPER MOTOR 488
SWITCH PANEL-REAR DOOR SERVICES 489
SWITCHES – TAILGATE FUNCTIONS 490
INTERIOR LAMP 490
HIGH LEVEL STOP LAMP 491
HIGH LEVEL STOP LAMP BULB 491
RADIO SPEAKER – REAR 492
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