Land Rover Defender 90 110 Workshop Book 4 Rover

							BRAKING SYSTEM I70 I 
.. ,. Renewing secondary  plunger seals 
14. Remove the  following items from the plunger: 
f ,*: 
(a) spring 
(b)  seal  retainer 
(c)  recuperating seal 
(d)  washer 
outer  seal. 
15. Taking care  not to damage  the plunger  prise off the 
a 
 b d 14 \I I 
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15 
ST1198M 
16. Fit a new  outer  seal using  the  same  procedure  as 
for  the  primary  plunger outer seal by  squeezing  the 
seal  between  the finger  and  thumb into  an  ellipse 
and  press  the raised  part 
of the seal  over  the flange 
using  the fingers 
of the  other  hand. 
17. Fit  the  recuperating  seal  assembly parts in the 
reverse  order 
of removal. 
Assembling  master cylinder 
It is important  that  the following  instructions  are 
carried  out precisely,  otherwise  damage  could be 
caused  to the new seals  when  inserting  the plungers into 
the  cylinder  bore.  Generous amounts of  new brake 
fluid  should  be  used 
to lubricate  the  parts during 
assembly.  Never use old fluid  or any  other  form 
of 
cleaning  and lubricating  material.  Cleanliness 
throughout  is essential. 
18. Clamp  the cylinder  in a vice and lubricate  the 
secondary  plunger  seals  and cylinder  bore. Offer 
the  plunger  assembly  to the  cylinder  until the 
recuperation  seal 
is resting  centrally  in the  mouth 
of the  bore.  Gently  introduce  the plunger  with a 
circular  rocking motion,  as  illustrated. Whilst 
ensuring  that the  seal  does not become  trapped, 
ease  the  seal into  the  bore  and slowly  push the 
plunger down  in one  continuous movement. 
-k ss. 
II 18 
ST 1 ZOOM 
19. 
20. 
21. 
22. 
23. 
24. 
Fit  the  primary  plunger assembly  using the same 
method  as  for the  secondary  plunger.  Press  the 
plunger  down  and  secure the assembly  with 
the 
plastic circlip. 
Slowly  press the plunger  down  the bore and  fit the 
secondary  plunger stop
-pin. 
Lubricate  new seals  and 
fit to the inlet  ports  (large 
diameter  downwards). 
Press  the reservoir  into position  and secure  with 
the 
two m!I pins. 
Fit  a new  washer  to the  reservoir  cap and  press  the 
plastic baffle  into position inside  the cap. 
Fit  a new  rubber seal  to the  cylinder  flange and  fit 
the  master  cylinder to  the servo  and  secure  with 
two nuts  and spring  washers. 
ST1199M 
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							BRAKING SYSTEM 
Incorrect linings. Badly lined shoes.  Distorted 
shoes.  Overloaded  vehicle. Excessive 
braking.  Old hydraulic fluid. 
BRAKING  SYSTEM 
FAULT  DIAGNOSIS 
Replace the shoes,  decrease vehicle load or renew hydraulic  fluid as necessary. 
FAULT I CAUSE I ACTION 
Air in system. Badly lined shoes. Shoes 
distorted or incorrectly  set. Faulty  drums. 
Weak  master  cylinder  mounting. 
FADE 
Check for air in the system  using a Hose Clamp 
and  bleed if necessary.  Check the master 
cylinder  mounting, lined shoes  and drums 
and replace 
as necessary. Renew the hydraulic 
fluid if appkdblc. 
Brakes  maladjusted. No clearance  at master 
cylinder  push rod. Seals swollen. Siezed pistons. 
Shoe  springs weak 
or broken. Servo faulty. 
SPONGY 
PEDAL 
Check the brake adjustment.  Check for clearance 
at the master  cylinder, siezcd pistons or weak 
shoe  springs.  Repair or replace parts as necessary. 
HARD 
PEDAL- POOR  BRAKING 
BRAKES PULLING 
FALL  IN FLUID LEVEL 
LONG 
PEDAL 
Incorrect linings. Glazed linings.  Linings  wet, 
greasy or not  bedded  correctly. Servo unit inoperative.  Siezed caliper pistons. 
Worn shock  aborbers causing wheel  bounce. 
Siezed  pistons.  Variation  in linings.  Unsuitable 
tyres 
or pressures.  Worn shock  absorbers. 
Loose brakes.  Greasy linings. Faulty drums, 
suspension 
or steering. Contaminated  seals. Replace 
the shoes, 
or if glazed,  lightly rub down 
with  rough  sandpaper.  Check caliper  for damage 
and repair 
as necessary.  Check servo. 
Fit new  shock absorbers. 
Check 
thc tyres and pressures,  seized pistons, 
greasy linings, or loose brakes;  then check 
suspension, steering  and drums. Repair 
or replace as necessary. Fit new  shock 
absorbers. Recti@ contamination,  fit new seals 
and  hoses. 
Chcck the pads  for wcar and for hydraulic  fluid 
Worn  disc pads. External leak. Leak  in Scrvo 
A. 
Disc  Brakes 
Discs  running  out 
pushing  pads back. 
Misplaced  dust covers. 
B. Drum Brakes 
Brakes  need adjustment. 
Fluid  leak. 
Fluid  contamination.  Wom 
or swollen seals in master cvlinder. Blocked  filler caD vent.  ~~~~~~~~~  ~ 
UNEVEN 
OR EXCESSIVE 
PAD  WEAR  A. 
Check  the disc 
run out  does  not exceed 0,lO mm (0.004 in) 1. Rotate  the disc on the hub. 2. Check  the didhub mounting  faces. 
and  for fluid  leaks.  Adjust brakes, repair leak, 
if necessary, or renew  seals and change  fluid. 
B. Check the brake  adjustment,  filler cap vent 
Disc  corroded (by  salt). Disc badly  scored. Pads 
scored.  Pads require  interchanging.  Incorrect 
friction  material.  Check 
the disc 
for corrosion. or scoring  and 
replace if necessary.  Alternatively,  interchange 
pads. Fit new  pads  with correct  friction  material. 
BRAKES BINDING 
1 Unit. I leakage. 
DISC  BRAKE 
SQUEAL- PAD RATTLE 1 Worn retaining pins.  Worn discs.  Renew the 
retaining pins, or discs.  Apply  disc I brake lubricant  to back of pads. 
14  
						

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							76 
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CHASSIS AND BODY 
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							CHASSIS AND BODY 
A FrontDatum 
B Chassis Datum 
C  Front  axle centre  Iine 
D Rear axle centre  line 
1. 239,O-236,5 mm 
2. 82,O-79,5 mm 
3. 633 mm 
4. 2420,6-2418,6 mm 
5. 2306,4-2305,4 mm 
6. 981,2-978,7 mm 
7. 182,7 mm 
8. 41,5-37,O mm 
9. 252-250 mm - . .. 10. 110 mm 
11. 2360 -Wheelbase 
12.  636 - 654 mm 
13. 488-483 mm 
14. 488-483 mm 
15. 3431,l-3426,l mm 
16. 588,3 - 586,3 mm 
17. 2313,8-2311,8 mm 
18. 590,5 mm 
19. 295,25 mm 
20. 519,60 - 517,OO mm 
21. 259,80-258,50 mm 
22. 1242,6 - 1240,6 mm 
23. 6423-66393 mm 
24. 750,9 mm 
LAND ROVER 90 
CHASSIS ALIGNMENT DIMENSIONS 
25. 639,5-436,5 mm 
26. 136,5 mm 
27. 299,5-295,5 mm 
28.  103 - 100 mm 
29. 131,5-- 126,5 mm 
30. 7053 - 7043 mm 
31. 7053 - 7043 mm 
32. 42,2-40,2 mm 
33. 491 - 486 mm 
34. 594,2-593,4 mm 
35. 283,O-2282,2 mm 
36. 32,25 - 31,25 mm 
37. 397 - 395 mm 
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							76 
N 
CHASSIS AND BODY 
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							CHASSIS AND BODY El 
.. . . .... r”,,.. ’: ., , . :I 4.:: : . ... .~. 
A FrontDatum 
B Chassis Datum 
C Front axle centre line 
D  Rear axle centre 
line 
1. 4148 - 4143 mm 
2. 40093-4005 mm 
3. 978,7-981,2 mm 
4. 22-20” 
5. 252-250 mm 
6. 239-236,5 mm 
7. 3023,3-3022,3 mm 
8. 3030,7-3028,7 mm 
9. 155- 153 mm 
10. 871,2-869,2 mm 
11.  2794 mm - Wheelbase 
12. 488 - 433 mm 
13. 488 - 433 mm 
14. 82-79,5 mm 
15. 750,9 mm 
16. 750,9 mm 
17. 4393 - 4363 mm 
18. 4393 -4363 mm 
19. 2993 - 2953 mm 
20. 500-495 mm 
21. 500 - 495 mm 
22. 594,2-593,4 mm 
-- 
LAND ROVER 110 
CHASSIS  ALIGNMENT  DIMENSIONS 
23. 594,2 - 593,4 mm 
24. 283 - 282,2 mm 
25. 283 - 282,2 mm 
26. 1970- 1968 mm 
27. 642,9-639,5 mm 
28. 590,5 mm 
29. 295,25 mm 
30. 136,5 mm 
31.  103 - 100 mm 
32. 1177,5- 1175,5 mm 
33. 1692,5 - 1689,5 mm 
34. 2610-2606 mm 
35. 2040,5 -2037,5 mm 
36. 1912,5 - 1909,5 mm 
37. 1359- 1357 mm 
38. 1573- 1571 mm 
39. 270 - 268 mm 
40. 665,5-633,5 mm 
41,  440 - 438 mm 
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							.  
						

							CHASSIS AND BODY 1761 
DOORS - 1986 ONWARDS 
7  
						

							176 I CHASSIS AND BODY 
REMOVING THE DOOR TRIM - Front and rear 
doors 
1. Prise off the  two  finishers  and remove  the two 
screws  securing  the door  pull. 
-. -- .___ - ...- . 
1. 
5. Lever off the window  regulator center finisher and 
remove  the retaining  screw and withdraw  the 
handle  and bezel. 
2. Remove the single Screw behind the remote control 6- Using a screwdriver, the trim away 
lever. from the door. 
3. Prise off the remote  control  lever bezel. Fitting  door trim 
7. Remove  any trim  fasteners  held in the  door  panel 
and  insert  them into the back 
of the trim  or use  new 
ones. 
8. Ensure  that the anti-vibration pads  are in position 
and  offer
-up the  trim  to the  door,  lining-up the 
fasteners  with the holes  in the  door  and push  the 
trim  into position. 
4. Prise off the door  locking  button bezci. 
, 
8