Land Rover Defender 90 110 Workshop Book 1 Rover

							SLRSZ1EìWh.I  
						

							TABLE OF CONTENTS 
SECTION 
Introduction 
mI ........................................................................\
.............................. 
........................................................................\
........... 
El 
General  Specification  Data 
.......................... Engine Tuning  Data.. .I!. ............................................................. 
........................................................................\
............. Torque  Wrench  Settings.. mb 
........................................................................\
.......... mI General  Fitting Instructions 
..................................................... 
........................................................................\
............................. El 1 
Recommended  Lubricants, Fluids and Capacities.. 
Maintenance 
El 
El 
El 
Engine ........................................................................\
..................................... 
,~ Cooling  System ........................................................................\
.......................... 
..................................................................... Fuel System (including  Fuel Injection) 
... . ..I 
Clutch.. ........................................................................\
.................................... OJ 
........................................................................\
. w 
El 
w 
Manual  Gearbox  and Transfer  Box 
Propeller  Shafts.. 
Rear Axle and Final  Drive 
........................................................................\
........................ 
........................................................................\
............ 
........................................................................\
..................................  Steering.. 
Suspension 
........................................................................\
................................ 
Brakes ........................................................................\
..................................... 
Electrical ........................................................................\
.................................. 
BOOK 
2 
5  
						

							BOOK ONE CONTENTS 
05 
Page 
ENGINE TUNING DATA 
Section 
Number 
ri 
-Repairs and replacement  parts 
- Poisonous substances 
-Fuel handling precautions 
-Fuel tank draining  and repair J 
.. - 
- Service  tools 5 
- Location of vehicle identification  numbers 6 
06 TORQUE WRENCH SETINGS 
El GENERAL SPECIFICATION  DATA 
- V8 engine data 
-2.25 litre petrol  engine  data 
-2.25 litre petrol  engine data 
- 2.25 litre dicscl cnginc data 
-2.50 litre dicsel  engine  data 
- General  data - all models 
-Tyre  pressures 
- Replacemcnt bulbs  and units 
- Vchiclc wcights 
1 
3 
5 
7 
9 
11 
19 
19 
20 
- V8 engine  tuning data 
-2.25 litre petrol  engine  tuning data 
- 2.5 litre petrol  engine  tuning data 
-2.25 and 2.50 litre dicscl engine  tuning data 
7 
:I.. i , .. . ... ,.. .E. , 
1  
						

							Book One Contents (cont’d) 
07 
Section 
GENERAL FITTING INSTRUCTIONS 
-Precautions  against damage 
-Safety precautions 
-Preparation  and dismantling 
-Inspection of components 
-Ball  and roller  bearings 
- Oil seals 
-Joints  and joint  faces 
- Flexible  hydraulic  pipes and hoses 
- Metric  bolt identification 
- Metric  nut identification 
- Hydraulic  fittings 
- Keys and keyways 
-Tab washers,  split pins,  nuts and locking  wire 
- Screw threads 
- Unified  thread identification 
1091 RECOMMENDED  LUBRICANTS, FLUIDS AND CAPACITIES 
1 
1 
1 
2 
2 
2 
3 
3 
3 
4 
4 
5 
5: 
5 
6 
- 
- Recommendcd lubricants 
- Anti-freeze  proportions 
-Corrosion  inhibitor 
-Capacities 
-Maintenance  Schedules 
-Maintenance - lubrication 
-Maintenance - general maintenance  and adjustments 
2  
						

							01 
fi;y :i: INTRODUCTION ... ,:.; :.? , ... ..:I. .!I, I . ._ ...,., , . ... 
This Workshop  Manual covers the Land  Rover  Ninety  and One  Ten range of vehicles.  It is primarily  designed to 
assist  skilled  technicians  in the  efficient  repair and maintenance  of Land  Rover  vehicles. 
Using  the appropriate  service tools and carrying  out the procedures  as detailed  will enable  the operations  to 
be 
completed within the time stated  in the  Repair  Operation  Times. 
The Manual has been  produced  in separate  books; this allows  the information  to be  distributed  throughout  the 
specialist  areas 
of the modern service facility. 
A table of contents  in Book 1 lists the major  components  and systems  together  with the section  and book  numbers. 
The  cover  of each  book  details  the sections  contained  within that book. 
The  title page 
of each  book  carries  the part  numbers  required to order  replacement  books, binders  or complete 
Service  Manuals.  This can be done  through  the normal  channels. 
REFERENCES 
References to the left- or right-hand side in the manual  are made  when viewing  the vehicle  from the rear.  With  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.  It 
is essential  that work  is inspected  and tested  after completion  and if necessary a road  test of the  vehicle  is carried  out 
particularly  where safety related  items are concerned. 
DIMENSIONS 
The  dimensions  quoted are to design engineering  specification.  Alternative unit equivalents,  shown in brackets 
following  the dimensions,  have been converted  from the original  specification. 
During  the period 
of running-in from  new, certain  adjustments  may vary  from  the specification  figures given in this 
Manual.  These adjustments  will be re
-set  by the  Distributor  or Dealer  at the  After  Sales Service,  and thereafter 
should  be maintained  at the  figures  specified 
in the Manual. 
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 and 
accessories: 
Safety  features  embodied  in the  vehicle  may be impaired 
if other  than Land  Rover  parts are fitted.  In certain 
territories,  legislation prohibits the  fitting of parts  not to the  vehicle  manufacturers  specification. Torque wrench 
setting  figures  given 
in the Repair  Operation  Manual must bc strictly  adhered  to. Locking  devices, where specified, 
must  be fitted.  If the  efficiency  of a locking  device is impaired  during removal 
it must be  renewed.  Owners 
purchasing  accessories  while travelling  abroad should ensure that the accessory  and its fitted  location 
on the vehicle 
conform 
to mandatory  requirements  existing in their  country  of origin.  The terms of the Owners  Service Statement 
may  be invalidated  by the  fitting  of 
other than Land  Rover  parts. 
A11 Land Rover  parts have the full backing of the Owners  Service Statement. 
Land  Rover  Distributors  and Dealers  are obliged  to supply only  Land Rover  service  parts. 
POISONOUS  SUBSTANCES 
Many liquids and other  substances  used in motor vehicles  are poisonous  and should  under no circumstances  be 
consumed  and should  as far 
as possible  be kept  away  from open  wounds.  These substances  among others include 
antifreeze,  brake fluid, fuel, windscreen  washer additives,  lubricants  and various  adhesives. 
FUEL HANDLING PRECAUTIONS 
The following  information  provides basic precautions  which must be observed if petrol  (gasoline)  is to  be  handled 
safely.  It also  outlines  the other  areas of risk  which  must 
not be ignored. 
This  information  is issued  for basic  guidance  only, and in 
any case of doubt  appropriate  enquiries should be made  of 
your  local  Fire Officer. 
GENERAL 
Petrol/gasoline vapour is highly  flammable  and in confined  spaces is also  very  explosive  and toxic. 
When 
petroI/gasoline evaporates  it produces 150 times  its own volume in vapour,  which when diluted  with air 
readily  be distributed  throughout  a workshop  by air  current,  consequently,  even a small  spillage  of 
petrol/gasoline is 
potentially  very dangerous. 
.. . .... . becomes  a readily  ignitable  mixture. The vapour  is heavier  than air and  will always  fall to the  lowest  level. It can 
3  
						

							lo1 I 
Always have a fire  extinguisher  containing FOAM CO? GAS, or POWDER  close at hand  when  handling  or draining 0 
fuel,  or when  dismantling  fuel systems  and in areas whcre fuel containers  are stored. 
Always  disconnect  the vehicle  battery BEFORE  carrying out dismantling  or draining  work 
on a fuel system. 
Whenever 
petroVgasoline is  being  handled,  drained or stored,  or when  fuel systems  are being  dismantled  all forms  of 
ignition  must be extinguished  or removed,  any 
hcad-lamps used must  be flameproof  and kept  clear  of spillage. 
NO ONE  SHOULD  BE PERMITTED  TO REPAIR  COMPONENTS  ASSOCIATED WITH PETROL/ 
GASOLINE  WITHOUT FIRST HAVING  HAD SPECIALIST  TRAINING. 
FUEL TANK DRAINING 
WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED  OR DRAINED  FROM ANY VEHICLE WHILST 
IT 
IS STANDING  OVER A PIT. 
Draining or extracting petrol/gasoline from  vehicle  fuel tank  must  be carried  out in a well  ventilated  area. 
The  receptacle  used to contain  the 
petroVgasoline must be more  than adequate  for the  full  amount  of fuel  to be 
extracted  or drained.  The receptacle  should be clearly  marked  with its contents,  and placed in a safe  storage  area 
which  meets the requirements  of local  authority  regulations. 
WHEN 
PETROWGASOLINE HAS  BEEN  EXTRACTED  OR DRAINED  FROM A FUEL TANK  THE 
PRECAUTIONS  GOVERNING NAKED LIGHTS 
AND IGNITION  SOURCES SHOULD BE MAINTAINED. 
FUEL TANK REMOVAL 
On vehicles where the fuel  line is secured to the  fuel  tank  outlet  by a spring  steel clip, it is recommended  that such 
clips  are released  before the fuel  line is disconnected  or the  fuel  tank  unit is removed.  This procedure  will avoid  the 
possibility  of residual  petrol fumes in 
the fuel tank  being  ignited  when the clips  are released. 
As  an added  precaution  fuel tanks  should  have a 
PETROUGASOLINE VAPOUR  warning label attached to them 
as  soon  as they  are removed  from 
the vehicle. 
fi-- k. 
FUEL TANK REPAIR 
Under no circumstances  should a repair  to any  tank  involving  heat treatment  be carried  out without  first rendering 
the  tank  SAFE,  by using 
one of the  following  methods: 
STEAMING:  With the filler  cap and  tank  unit removed,  empty the tank.  Steam  the tank  for at least  two hours 
with  low pressure  steam.  Position the tank 
so that  condensation  can drain  away freely,  ensuring  that any 
sediment  and sludge  not volatised  by the  steam,  is washed  out during  the steaming  process. 
BOILING:  With the filler  cap and  tank  unit removed,  empty the tank.  Immerse  the tank  completely  in boiling 
water  containing 
an effective  alkaline degreasing  agent or a detergent,  with the water filling  and also 
surrounding  the tank  for at least  two hours. 
After  steaming  or boiling  a signed  and dated  label to this  effect  should  be attached  to the  tank 
SPECIFICATION 
Purchasers  arc advised  that the specification  details set out  in this  Manual  apply to a rangc of vehicles  and not to any 
one.  For the specification  of a particular  vehicle, purchasers  should consult  their Distributor  or Dealer. 
The  Manufacturers  reserve 
thc right to vary their  specifications  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 Manufacturers 
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 
thercof. 
COPYRIGHT 
@Land Rover  Limited 1984 
All rights reserved.  No part of this  publication  may be produced,  stored in a retrieval  system or transmitted  in any 
form,  electronic,  mechanical,  photocopying,  recording or other  means  without  prior written  permission 
of Land 
Rover  Limited,  Service Department,  Solihull, England. 
4  
						

							- Special Service Tools 
The use of approved  special service  tools is important.  They are essential if service  operations 
are 
to be  carried  out efficiently,  and safely.  The amount of time  which  they save  can  be 
considerable. 
Every  special  tool is designed  with the close  co
-operation of Land  Rover  Ltd., 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. 
Countfies where  there is no  distributor  may order  direct  from V. L. Churchill  Limited. P.O. 
Box 3, Daventry,  Northamptonshire,  England NNll 4NF. 
The  tools  recommended 
in this Workshop  Manual are listed  in a multi-language,  illustrated  catalogue obtainable 
from  Messrs. 
V. L. Churchill  at the  above  address  under publication  number 2217/2/84 or from  Land  Rover  Ltd., 
under  part number 
LSM0052TC from thc following  address, Land Rover  Limited,  Service Department, Lode Lane, 
Solihull,  West Midlands,  England B92 8NW. 
5  
						

							LOCATION OF VEHICLE IDENTIFICATION  AND UNIT  NUMBERS 
VEHICLE  IDENTIFICATION  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
-hand  side of 
the  chassis  forward 
of the spring  mounting  turret. 
Always  quote this number  when writing  to Land  Rover 
Limited. 
Key  to Vehicle  Identification  Number Plate 
A Type approval 
B VIN (minimum of 17 digits) 
C Maximum  permitted laden weight  for vehicle 
D Maximum  vehicle and trailer  weight 
E Maximum road weight - front  axle 
F Maximum  road weight - rear axle 
I 
I 
I 
fAND 
&IR 
TOO1 
ST037 I 
ENGINE  SERIAL NUMBER - VS ENGINE 
The V8 engine serial number  is stamped on a cast  pad 
on the  cylinder  block between  numbers 3 and 5 
cylinders. 
6 
ST 
ENGINE  SERIAL NUMBER - 4 CYLINDER 
ENGINES 
The 4 cylinder  engine number  is stamped  on a 
machined  surface at the  front  left
-hand side of the 
On  later  engines  the number  is stamped  above the rear 
side  cover,  as the  second  illustration  shows. 6” engine adjacent  to the  exhaust  manifold  front flange. -. -  
						

							LOCATION OF VEHICLE IDENTIFICATION  AND UNIT  NUMBERS 
ST663M 
01 
FRONT  AXLE 
Stamped  on top of the  left-hand  axle tube. 
REAR  AXLE 
Stamped  on rear of left-hand  axle tube. 
MAIN  GEARBOX  LT77 - 4 CYLINDER  VEHICLES 
Stamped on a pad  on the  right-hand  side of the  gearbox 
immediately  below the 
oil filler level plug. 
U 
ST665M 
TRANSFER  GEARBOX LT230R - 4 CYLINDER 
VEHICLES 
Stamped  on the  casing  on the  left-hand  side of the 
gearbox  below the mainshaft  rear bearing  housing 
adjacent  to the  bottom  cover. 
Y ST664M 
TRANSFER  GEARBOX LT230T - 4 CYLINDER 
AND  V8 VEHICLES  FROM SERIAL  NUMBER 
SUFFIX 
‘B’ ONWARD 
MAIN  GEARBOX 
LT85 FIVE SPEED - V8 
VEHICLES 
Stamped  on the  right-hand  side of the front  bearing 
plate. 
STl546M 
7  
						

							GENERAL SPECIFICATION DATA 
ENGINE 
Type ................................................................. 
Number of cylinders ............................................. 
Bore ................................................................. 
Stroke ............................................................... 
Capacity ............................................................ 
Valve operation.. ................................................. 
Maximum  power- B.H.P ..................................... 
Maximum power - KW.. ...................................... 
Maximum  torque ................................................. 
04 
V8 
Eight, two banks of four 
88,90 mm (3.500  in) 
71,12 mm (2.800 in) 
3528 
cc (215 in) 
Overhead by push-rod ._ 
13 } at 4000rpm 84.6 
251 
Nm (185 lb  ft)  at 2500 rpm 
Crankshaft 
Main  journal  diameter ....................................... 
Minimum  regrind diameter .............................. 
Crankpin  journal diameter. 
Minimum  regrind diameter 
.............................. 
Crankshaft  end thrust ........................................ 
Crankshaft  end-float .......................................... 
58,409 - 58,422 mm (2.2996 - 2.3001 in) 
57,393 - 57,406 mm (2.2596 - 2.2601 in) 
50,800 - 50,812 mm (2.0000 - 2.0005 in) 
49,784 
- 49,797 mm (1.9600 - 1.9605  in) 
Taken 
on thrust  washers of centre  main bearing 
0,lO - 0,20 mm (0.004 - 0.008 in) 
.. ................................. 
Main  bearings 
Number  and type .............................................. 5, Vandervell  shells 
0,010 
- 0,048 mm (0.0004 - 0.0019  in) 
0,254 
mm, 0,508 mm (0.010  in, 0.020  in) 
Material 
......................................................... Lead-indium 
Diametrical  clearance 
........................................ 
Undersizes ...................................................... 
Connecting rods 
Type.. ............................................................ Horizontally  split big end, pIain small  end 
Length  between  centres 
...................................... 143,81 - 143,71 mm (5.662 - 5.658 in) 
Big end bearings 
Type  and material ............................................. 
Diametrical  clearance ....................................... 0,015 - 0,055 mm (0.0006 - 0.0022 in) 
End
-float  on crankpin ....................................... 0,15 - 0,36 mm (0.006 - 0.014 in) 
Undersizes 
...................................................... 
Vandervell VP lead-indium 
0,254 
mm, 0,508 mm (0.010 in, 0.020  in) 
Gudgeon pins 
Length ........................................................... 72,67 - 72,79 mm (2.861 - 2.866 in) 
Fit
-in  connecting  rod ......................................... 
Clearance in piston ............................................ 0,002 - 0,007 mm (0.0001 - 0.0003 in) 
Diameter 
........................................................ 22,215 - 22,22 mm (0.8746 - 0.8749 in) 
Press fit 
Pistons 
Clearance 
in bore measlured at hottom of skirt at 
right angles  to gudgeon  pin .................................. 0,018 - 0,033 mm (0.0007 - 0.0013 in) 
1