Land Rover Defender 90 110 Workshop Book 1 Rover
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MAINTENANCE 7. Assemble the contact breaker spring insulating bushes and electrical leads, as illustrated, in the following sequence: (a) lower bush (b) spring (c) low tension lead (d) capacitor lead (e) top bush and secure with the anchor spring nut. cam lubrication pad. 8. Apply a few drops of engine oil to the distributor Sliding contact type RR090 3,lO- 3 Adjust points -both types 9. Turn the engine in the direction of rotation until the contacts are fully open or the heel of the contact set is on the highest point of the cam. 10. Using a feeler gauge and the dwell angle adjuster on the side of the distributor, set the points to a nominal gap of 0,35 to 0,40 mm (0.014 to 0.016 in). 11. At the earliest opportunity check and adjust the dwell angle - see data - using spccial turning equipment. 12. Fit the rotor arm and distributor cap ensuring that the H.T. pick-up brush moves freely. I -- *. 1 L .. -.. 0 1. Release the clips and remove the distributor cap. 2. Remove the rotor arm from the cam spindle. 3. Remove the retaining screw and washers and lift the complete contact breaker assembly from the moveable plate. 4. Remove the nut and plastic bushes from the terminal post to release the leads and spring. 5. Discard the old contact breaker assembly. 6. Clean the new points with petrol to remove the 7. Connect the leads to the terminal post in the protective coating. following sequence: (b) red lead tab (c) contact breaker spring eye (d) black lead tab (e) upper plastic bush (f) retaining nut. the two pegs locate in the holes. (a) lower plastic bush ST1083M 8. Fit the contact set to the moving plate ensuring that 1s
MAINTENANCE I 10 I ;::;., CLEAN AND LUBRICATE V8 ENGINE y? DISTRIBUTOR Fixed contact type 1. Remove distributor cap. 2. Remove rotor arm. 3. Lightly smear the cam with clean engine oil. 4. Add a few drops of thin machine oil to lubricate the 5. Wipe the inside and outside of the distributor cap 6. Ensure that the carbon brush works freely in its 7. Refit rotor arm and distributor cap cam bearing and distributor shaft. with a soft dry cloth. holder. Sliding contact type 1. Remove distributor cap. 2. Remove rotor arm. 3. Lightly smear the cam with clean engine oil. 4. Add a few drops of thin machine oil to lubricate the cam bearing and distributor shaft. 5. Wipe the inside and outside of the distributor cap with a soft dry cloth. 6. Ensure that the carbon brush works freely in its holder. 7. Lubricate the actuator ramps and contact breaker heel ribs with Shell Retinax or equivalent grease. 8. Grease the underside of the heel actuator. CLEAN AND LUBRICATE DUCELLIER DISTRIBUTOR 1. Remove the distributor cover and lift off the rotor arm and anti-dust shield. 2. Inspect the contact breaker points; if burnt or worn they should be renewed. 3. Very lightly smear the cam with grease - Shell Retinax. 4. Lubricate the pressure pad with grease - Shell Retinax. 5. Add a few drops of oil to the felt pad in the top of the cam spindle. 6. Turn the engine until the distributor centrifugal weight pivot post is visible through the cut -out in the base plate and lubricate the pivot post with a drop of oil. Repeat for the opposite pivot post. 7. Carefully wipe away all surplus lubricant; and ensure that the contact breaker points are clean and dry. 8. Fit the anti-dust shield. 9. Refit the rotor arm, engage the slot in the spindle and push down firmly. 10. Wipe clean with dry nap-free cloth, the inside and outside of the distributor cover, particularly between the electrodes, and fit the distributor cover. 9. Apply grease to the fixed pin and actuator fork. CLEAN V8 ENGINE ELECTRONIC IGNITION DISTRIBUTOR 10. Refit rotor arm and distributor cap. RR092 80.000 km (48,000 miles) Remove the distributor cap and rotor arm and wipe inside with a nap-free cloth. DO NOT DISTURB the clear plastic insulating cover which protects the magnetic pick-up module. 19
MAINTENANCE CLEAN AND LUBRICATE LUCAS DISTRIBUTOR 1. Clean and lightly grease the cam with Shell Retinax or equivalent and remove any surplus lubricant. 2. Using the same grease lubricate the underside of the heel actuator. 3. Grease the actuator ramps and contact breaker heel ribs. 4. Apply grease to the fixed pin and the actuator fork. 5. Apply a drop of clean engine oil to the felt pad underneath the rotor arm. 6. Every 40.000 km (25,000 miles) lubricate the automatic advance mechanism by injecting one or two drops of engine oil through the aperture in the base plate. 7. Wipe the internal and external surfaces of the distributor cap with clean dry nap -free cloth and fit the cap to the distributor body. 3 ST1084M 3 2 ST CHECK AND ADJUST VS ENGINE DISTRIBUTOR TIMING Using Electronic Timing Equipment A pointer on the timing cover and marks on the crankshaft pulley indicate positions around T.D.C. on No. 1 cylinder (i.e. front cylinder on left-hand bank). Refer to Engine Tuning data for appropriate ignition timing. Engine speed accuracy during ignition timing is important. Any variation from the required idle speed, particularly in an upward direction, will lead to wrongly set ignition timing. 1. Connect a stroboscopic timing light as instructed by the manufacturer. The engine is timed on No. 1 cylinder. 2. Run the engine at idle speed. 3. Position the timing light to illuminate the crankshaft pulley and scale. - WARNING: Ensure that personnel and equipment are kept clear of the rotating cooling fan while using the timing light. t- 1. . 4. If the timing is correct the pulley mark indicated in the Tuning Data will show. If correct, instruction 5 may be ignored. 5. With the engine still running at idle speed, slacken the clamp bolt and carefully rotate the distributor body as required until the correct pulley mark shows. Turn anticlockwise to advance and clockwise to retard. 6. Tighten the clamp bolt with the unit in this position. g !, A, . .. 20
MAINTENANCE I 10 I I, 1 *-‘r!t di. CLEAN, ADJUST OR RENEW SPARK PLUGS Refit or renew spark plugs .i;C’ I -2, . . 1. Withdraw the H.T. leads from the spark plugs by 2. Using an appropriate plug spanner, remove the gripping the shrouds, do not pull on the leads. spark plugs. ST1087M 11. Check that the washers are fitted to the plugs. 12. It is important that only spark plugs specified in Data section are used for replacements. 13. Incorrect grades of plug may lead to piston over- heating and engine failure. 14. Wash new plugs in petrol to remove the protective coating, then set the electrode gaps to the appropriate figures given in ‘Engine Tuning data’. 15. Fit the plugs and washers to the engine but do not overtighten. 16. Examine high tension leads, including the coil to distributor lead, for insulation cracking or corrosion at end contacts. Fit new leads as necessary. 17. In addition to correct firing order, high tension leads must be fitted in correct relation to each other to avoid cross firing, as illustrated. This is particularly important on the V8 engine. First illustration. 4 -cylinder engine. Second illustration. V8 engine. shrouds are firmly seated on plugs. Clean and set gaps 18. When pushing leads on plugs ensure ferrules within 3. Fit plug in plug cleaning machine. 4. Wobble plug with circular motion while operating abrasive blast for a maximum of four seconds. .. CAUTION: Excessive abrasive blasting will erode insulator nose. 5. Change to air blast only and continue to wobble plug for a minimum of thirty seconds to remove abrasive grit from plug cavity. 6. Wire -brush plug threads, open gap slightly. 7. Using point file, square off electrode surfaces. 8. Set electrode gap, see ‘Engine Tuning data’, 9. Test plugs in accordance with cleaning machine manufacturer’s instructions. If satisfactory, refit plugs in engine. 10. If no machine is available carefully wire brush electrodes and blow or wash away carbon particles. Illustration shows: A. Dirty or unsatisfactory electrode B. Filing plug electrodes C. A clean plug correctly set ST052 A B C ST051 21
1x1 MAINTENANCE CLEAN AND TEST HEATER PLUGS - Diesel CHECK BRAKE FLUID RESERVOIR engines REMOVE THE PLUGS 1. Check the fluid level in the fluid reservoir by observing the level in relation to the ‘MIN’ or ‘MAX’ marks on the side of the translucent reservoir. 2. If the level is below the ‘MAX’ mark clean the outside of the filler cap and top -up with new, clean fluid from a sealed container. Use only fluid recommended in the ‘General specification data’ section. Refit the cap. 1. Disconnect the battery. 2. Remove the terminal nut from each heater plug. 3. Detach the heater plug lead and washer from each 4. Remove the heater plugs. Plug. Clean and inspect 5. Remove carbon from base of heater plugs to avoid the possibility of short circuiting of the element. Do not sandblast. 6. Examine the element for signs of fracture and deterioration and the seating for scores. Plugs with fractures or doubtful elements must be renewed. Where scoring of the seating may impair the sealing, the plug should be renewed. Test and refit 7. Test the plug internal circuit for continuity by connecting it in circuit with a 12 volt side lamp bulb open circuit is indicated and the heater plug must be renewed. and a 12 volt supply. If the bulb does not light an ST 1088M STlOPlM 8. Ensure that the terminals are clean and that the thread at the base of the plug is free from carbon. 9. Fit the heater plugs to the engine. Do not overtigh ten. 10. Fit the heater plug lead and washer to each plug. 11. Connect the battery. CHECK CLUTCH FLUID RESERVOIR 1. Clean and remove the reservoir cap and observe the fluid level in relation to the marks on the side of the reservoir. 2. Top-up if necessary with new, clean fluid from a sealed container and of a recommended specification - see ‘General specification data’ section. Refit the cap. 22
, ,I- z:. CHECK POWER STEERING FLUID RESERVOIR I..::..,.. 3 ..... .“d .*:. .. c’: ,..‘.,. ^... , .. 1. Clean and remove the reservoir cap and observe the fluid level in relation to the mark on the side of the reservoir. 2. If necessary top -up with a recommended fluid - see ‘General specification data’ section - until the fluid is 12 mm (95 in) above the filter. Refit the cap. CHECK COOLING SYSTEM COOLANT Refer to the ‘Cooling system’ section for details of anti-freeze and inhibitors and to the ‘General specification data’ section for anti -freeze protection quantities. With a cold engine, the expansion tank should be approximately half full. WARNING: Do not remove the filler cap when the engine is hot because the cooling system is pressurised and personal scalding could result. To remove the filler cap, first turn it anti-clockwise a quarter of a turn and allow all pressure to escape, before turning further in the same direction to lift it off. When replacing the filler cap it is important that it is tightened down fuily, 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. // MAINTENANCE BATTERY Check Specific Gravity The specific gravity of the electrolyte should be checked using a battery hydrometer. The readings 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. As expected during normal service, three -quarter charged 1.230 to 1.250 specific gravity. If the specific gravity should read between 1.190 to 1.210, half-charged, the battery must be bench charged and the electrical equipment in the car should be checked. Tropical climate above 26.5”C (80°F) as commissioned for service, fully charged 1.210 to 1.230 specific gravity. As expected during normal service, three-quarter charge 1.170 to 1.190 specific gravity. If the specific gravity should read between 1.130 to 1.150, half-charged, the battery must be bench charged and the electrical equipment on the car should be checked. Check and Top-Up Electrolyte Level 1. Wipe all dirt and moisture from the battery top. 2. Remove the filler cover. If necessary add sufficient distilled water to raise the level to the top of separators. Replace the filler plugs or manifold lid. 3. Avoid the use of a naked light when examining the ceils. 4. In hot climates it will be necessary to top up the battery at more frequent intervals. 5. In very cold weather it is essential that the vehicle is used immediately after topping up, to ensure that the distilled water is thoroughly mixed with the electrolyte. Neglect of this precaution may result in the distilled water freezing and causing damage 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 for pulling down the terminal. 8. Do NOT disconnect the battery cables while the engine is running or damage to alternator semiconductor devices may occur. It 1s also inadvisable to break or make any connection in the alternator charging and control circuits while the engine is running. 9. It is essential to observe the polarity of connections to the battery, alternator and regulator, as any incorrect connections made when reconnecting cables may cause irreparable damage to the semiconducto r devices. IMPORTANT NOTE: If a new battery is fitted to the vehicle, it should be the same type as fitted to the vehicle when new. Alternative batteries may vary in size and terminal positions and this could be a possible fire hazard if the terminals or leads come into contact with the battery clamp assembly. When fitting a new battery ensure that the terminals and leads are clear of the battery clamp assembly. 23
MAINTENANCE REMEW BRAKE SERVO FILTER 1. 2. 3. 4. 5. 6. 7. Remove the nuts securing the master cylinder to the servo. Release the clip retaining the brake pipe to the clutch pipe. Separate the master cylinder from the servo. Disconnect the vacuum hose from the servo. Disconnect the Lucars from the stop lamp switch at the rear of the pedal box. Remove the blanking grommets from the pedal box. Remove the split pin from the clevis and withdraw the clevis pin and washer. 8. Remove the four nuts securing the servo to the pedal box and remove the servo. ST1533M i .- F 9. Pull back the dust cover. 10. Release the end-cap. 11. Cut the filters to remove them from the shaft. %L. ST1485M 12. 13. 14. Clean the filter seating and fit the new filters noting 6.- * that they must be cut to fit over the shaft. Fit the end-cap and dust cover and refit the servo and master cylinder to the vehicle reversing the removal procedure. Use a new split pin to secure the clevis. Test the brakes. 24
MAINTENANCE I 10 I ::... .. ! -j ENGINE SLOW RUNNING - 2.5 Diesel .;:y 1. Using a suitable tachometer, check the engine slow running adjustment see Engine tuning data. If adjustment is necessary slacken the locknut and turn the control screw clockwise to increase the revolutions and anti -clockwise to decrease the engine speed. Tighten the locknut, increase the engine speed for a few seconds then re-check the slow running. .. ST1425M 2. If a tachometer is not available adjust the control screw until the slowest speed is obtained consistent with smooth and even running. NOTE: The slow running control is the only permitted adjustment in service. Any additional adjustments required must only be carried out by authorised C.A.V. agents. 25