Land Rover Defender 90 110 Workshop Book 5 Rover

							Section 
Number 
rF* i=. ? - 
CONTENTS 
80 HEATER 
82 
-Remove and refit 
- Drive  belt adjustment 
AIR 
CONDITIONING  MAINTENANCE 
17 10 
. 
82 COMPRESSOR 
-Fan motors  remove  and refit 
-Condenser  rcmove and refit 
-Receiver drier  remove  and refit 
82 
18 
19 1 O 
CONDENSER 
82 
-Remove  and refit - L.H. Steering 
- Resistor  block - remove and refit 
-Blower  motor - R.H. Steering,  remove and refit 
EVAPORATOR 
20 
23 
24  
						

							Section 
Number 
86 
CONTENTS 
ELECTRICAL EQUIPMENT 
Page 
186 I ELECTRICAL PRECAUTIONS e 
-Polarity 
-High voltage  circuits 
- Connectors  and harncss 
-Battery disconnections 
-Battery  charging 
-General  precautions 
-Test equipment 
-Overhaul  V8 engine  distributor 
- Overhaul  four cylinder  engine distributor - Ducellier 
- Overhaul  four cylinder  cngine distributor - Lucas 
-Electronic  ignition distributor  type 35DMS - V8 engine 
-Electronic  ignition distributor  type 35DLM8 - V8 cngine 
-Overhaul  alternator - all models - Lucas Al 15-34 and  Al 15-45 
-Overhaul  alternator - all models - Lucas A127/65 
- Alternator  functional check 
-Diode fault symptoms 
-Alternator  fault and diagnosis  chart 
-Overhaul diesel engine  starter motor 
-Overhaul V8 engine  starter motor 
-Overhaul  four cylinder  petrol engine  starter  motor 
-Overhaul - Paris-Rhone 4 cylinder  Diesel engine  starter motor 
- Rcmovc  and refit  2.5 Turbo chargcd Diesel  engine  starter motor 
- Overhaul  Lucas M78R starter motor 
- Lamps 
- Overhaul  wiper motor  2 
4 
5 
7 
13 
pL 
20 k.;: 
24 
28 
29 
29 
30 
34  37 
41 
44 
45 
48 
52 
ELECTRICAL  EQUIPMENT 
- FAULT TRACING 
-Introduction 
-Charging systcm 
-Ignition system 
-Starter system  54 
55 
-. _, 
56 
60 
IS6 I CIRCUIT DIAGRAMS 
-Four  cylinder  petrol engine 
-2.25 litre  diesel  engine 
-2.5 litre  diesel  engine 
- V8 cylinder  engine 
-Composite  circuit diagram - 1986 onwards  all models 
- Dim-dip  circuit diagram 
-Twin Tank - Twin  pumps 
-Optional  equipment  circuit diagrams  64 
66 
68 
70  72 
74 
75 
76 
II  
						

							- . .. .aI 
I. 
Special Service Tools 
The use of approved  special service  tools is important.  They are essential if servicc 
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. Thc 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. 
A11 orders  and enquiries  from the Unitcd 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, 
PO Box 3 Daventry, Northants,  England 11 4NF. 
The tools  recommended in this Workshop  Manual are listed  in a multi-language, illustraicd catalogue 
obtainable  from 
Messers. V. L. Churchill  at  the above  address under  publication number 2217/2/84 or from 
Land  Rovcr  Ltd., under  part  number 
LSM0052TC from the following address, Land  Rovcr  Merchandising 
Scrvice, P.O. Box 534, Erdington, Birmingham B24 OQS. 
V  
						

							INTRODUCTION 
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’. 
e!, . . I, 
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  manufacturer’s specification.  Torque wrench 
setting figures  given in the Repair  Operation  Manual  must be 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 
thc 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. 
All 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 providcs 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. 
iii 
_. .  
						

							GENERAL 
Petrol/gasoline vapour is highly  flammable  and in confined spaces is also  very  explosive  and toxic. 
When 
petrol/gasoline evaporates  it produces 150 times  its  own  volume in vapour,  which when  diluted  with air 
becomes  a readily 
ignitablc mixture.  The vapour  is heavier  than air and  will always  fall  to the  lowest  level. It  can 
readily  be distributed throughout  a workshop  by air  current,  consequently,  even a small  spillage 
of petrol/gasoline is 
potentially  very dangerous. 
Always  have a 
fire extinguisher  containing FOAM CO2 GAS, or POWDER  close at hand when handling  or draining 
fuel,  or when dismantling  fuel systems  and in areas  where  fuel containers  are stored. 
Always  disconnect  the vehicle  battery  BEFORE  carrying out dismantling  or draining  work on  a fuel  system. 
Whenever 
petrol/gasoline is  being  handled,  drained or stored,  or when  fuel systcms are  being  dismantled  all forms  of 
ignition  must be extinguished  or 
removcd, any head-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/CASOLINE 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 
petrol/gasoline must  be more than adequate  for the  full  amount  of fuel  to be 
extracted 
or drained.  The receptacle  should bc clearly  marked  with its contents,  and  placed  in a safe  storage  arca 
which  meets  the requirements  of local  authority regulations. 
WHEN 
PETROL/GASOLINE HAS BEEN EXTRACTED  OR DRAINED  FROM A FUEL  TANK  THE 
PRECAUTIONS  GOVERNING NAKED LIGHTS  AND IGNITION  SOURCES SHOULD BE MAINTAINED. 
-+--, 8. a, 
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 
PETROL/GASOLINE VAPOUR warning  label  attached to them 
as soon  as they  arc removed  from the vehicle. 
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 
mcthods: 
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 
thc tank so that condensation  can drain  away frecly, 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 dcgreasing  agent  or a  detergent,  with the  water  filling and also 
surrounding 
thc 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  are advised  that the specification  details set out in this  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 specifications  with or without notice,  and at such times  and in 
such 
manner  as they think fit. Major  as well  as minor changcs 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 
!iab!e fer any inaccurxy or thc consequences  thereof. 
COPY RIGHT 
@ 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 
iv  
						

							HEATER 
REMOVE FROM VEHICLE 
1. Remove  bonnet and disconnect  battery. 
2. Remove radiator bottom hose at  radiator  union 
3. Slacken and remove  the heater  hoses at heater box 
4. Remove  outer cable securing  clips. 
5. Slacken and  remove  control  cables at  the  heater 
6. Remove  heater wiring  harness  securing  loop. 
7. Disconnect  harness multi-plug. 
8. Remove  interior bulkhead  trim. 
and 
drain cooling  system. 
unions. 
box. 
80 
. .. ST1887M 
OVERHAUL 
Fan  Motor  Assembly 
12. Remove the  nuts securing  the angled  bracket  to the 
heater unit,  and remove  the bracket. 
13. Remove  the five  nuts  securing  the fan asscmbly  to 
the heater  unit.  Unplug 
thc connector and remove 
the fan assembly [rom the heater  unit. 
14. Remove circlip holding  the impeller  to thc drive 
shaft and remove  the impeller. 
15. Remove  the  three  nuts  securing  the fan motor  to 
the mounting plate  and  release  the motor from  the 
plate. 
., .- -I . .. ,. 
9. Remove  lower nuts and  bolts  securing the  heater 
unit  to the  bulkhead. 
10. Slacken  heater unit upper  retaining  bolts. 
11. Manoeuvre heater  unit clear  of engine bay. 
1  
						

							80 
16. Fit fan  motor  into  mounting plate, apply  Rostik 
1261  adhesive  to mating  faces, and  secure 
with the 
three  nuts. 
17.  Refit impeller  to fan  drive shaft and 
fit circlip. 
18. Refit  fan  assembly to casing and  secure  with the 
19. Plug in connector  to resistor  harness  and  refit 
five nuts. 
angled bracket. 
HEATER 
Heater  Matrix 
20.  Drill  out rivets holding  the air duct  and top covcr to 
the casing.  (Three of the rivets  are concealed  by 
the  rubber  seal). 
21. Lift off cover, air duct and  seal. 
22.  Lift  heater matrix out of casing. 
23. 
Fit foam  rubber to heater  matrix  casing  and 
24.  Check  that 
flap valves  operate  correctly  and 
25.  Refit  top cover  and rivet  into place. 
position 
matrix 
in casing. 
without  sticking. 
Resistor  Unit 
26. Drill  out the four  rivets  retaining  the resistor 
mounting  plate, and lift out  plate  with resistor. 
27.  Apply  Bostik  adhesive  to resistor  plate  and  secure 
in  position  with rivets. 
REFIT  TO VEHICLE 
28.  Smear  heater  unit  sealing rubber with a suitable 
29. Piace neater unit into  engine  bay and manouevre 
30. Loosely fit lower  heater  unit nuts  and bolts. 
31.  Tighten  heater unit upper  securing bolts. 
32.  Tighten  lower nuts  and bolts. 
33.  Refit interior bulkhead  trim. 
34.  Locate  heater wiring harness  into securing  loop, 
2 
impact adhesive, and locate  to heater. 
into  position 
on bulkhead. 
and tighten  nut.  35. 
Connect  harness multi
-plug. 
36.  Refit  control cable  outer clip and  inner cable  pinch 
37. 
If necessary,  prime heatcr matrix with coolant 
bolts. 
mixture. 
22  
ST1888M W 
38. Conncct hoses to hcater unit  and tighten  hose  clips. 
39. Refit radiator  bottom  hose and refill  cooling 
system  with  the required  anti
-freeze  concentration 
or corrosion  inhibitor. 
40. Refit bonnet. 
41. Connect battery, start cnginc, and check for  leaks. 
42.  After  engine  has cooled  check  coolant 
level in thc 
expansion tank  and radiator. Top up if necessary.  
						

							f.l i h,4 .I. . General Service Information 
INTRODUCTION I- .. 
Before  any component of thc air conditioning system  is 
removed,  the system  must be depressurised.  When  the 
component  is replaced,  the system  must  be 
evacuatcd 
to remove  all traces  of old  refrigerant  and moisture. 
Then  the system  must  be recharged  with  new 
refrigerant. 
Any  service  operation  that  requires the  loosening  of a 
refrigerant  line connection  should  be performed  only 
by  qualified  service  personnel. Refrigerant 
and/or oil 
will  escape whenever a  hose 
or pipe is disconnected. 
All work  involving  the handling  of refrigerant requires 
special  equipment,  a knowledge  of its  proper  use and 
attention  to safety  measures. 
DO NOT - leave refrigerant  drum  without its  heavy 
cap fitted. 
- carry  refrigerant drum  inside a vehicle. 
- subject refrigerant  drums  to  high 
temperature. 
- weld  or steam  clcan near an  air 
conditioning  system. 
- expose eyes  to  liquid refrigerant, 
ALWAYS wear  goggles. 
- discharge refrigerant  vapour into an area 
with an  exposed  flame or into an engine 
intake.  Heavy concentrations  of 
refrigerant  in contact  with naked  flame 
produces a  toxic gas. 
- allow liquid  refrigerant  to contact  bright 
metal,  it will  tarnish  metal  and  chrome 
surfaces,  and  combined  with moisture 
can  seriously  corrode all metal  surfaces. 
Servicing equipment 
The following  equipment  is required  for full servicing PRECAUTIONS IN HANDLING REFRIGERANT 
of  the air  conditioning system. 
Charging 
trollcy 
Leak  detector 
Tachometer 
refrigerant connections.  LINES 
WARNING: 
Always  wear  safety goggles  when  opening 
Safety goggles 
Refrigerant  charging line gaskets 
Thermometer 
-20°C to -60°C 
Valvc Core Removers 
SERVICING  MATERIALS 
Rcfrigerant: Refrigerant 2, which includes  Freon 2 or 
Arcton 2. 
CAUTION:  Methychloride  refrigerants  must  not be 
used. 
Nominal  charge weight: 1,25 kg (2.75 Ibs). 
Compressor  oil: 
See Recommended  Lubricants. 
PRECAUTIONS IN HANDLING REFRIGERANT 
The refrigerant used in the air  conditioning  system is 
Refrigcrant 2, and  is transparent  and colourless in both 
the  gaseous  and  liquid 
statc. It  has a boiling  point of 
-2?.8OC (-21 2°F) at atmospheric p:essüre âm? a: all 
normal  pressures  and  temperatures it becomes  a 
vapour. 
The vapour  is heavier  than air, non-flammable, 
and  non
-explosive. It is  non-poisonous  except  when in 
contact with  an  open flame,  and non-corrosive until it 
comes  in contact  with water. 
The  following  precautions 
in handling Refrigerant  12 
should  be observed  at all times. 
. .,., .., ::. . ., I .. . I. 
(a) When  disconnecting  any  pipe or flexible 
connection  the system  must be  discharged  of 
all 
pressure.  Proceed  cautiously,  regardless of gauge 
readings. 
Open connections slowly, kccping hands 
and face  well clear, 
so that no injury occurs if there 
is liquid  in the  line.  If pressure  is noticed,  allow it 
to bleed off slowly. 
(b)  Lines,  flexible  end connections  and  componcnts 
must  be capped  immediately  they  are opened  to 
prevent  the entrance  of moisture  and dirt. 
(c)  Any  dirt or 
grcase on fittings  must  be wipcd off 
with  a clean  alcohol  dampened cloth. 
Do not use 
chlorinated  solvents  such  as trichloroethylene.  If 
dirt,  grease  or moisture  cannot be  removed  from 
inside 
the pipes, they must  be  replaced  with new 
pipes. 
(d) 
All replacement  components  and  flexible end 
connections  arc sealed, and should  only be 
opencd 
immediately  prior to making the  connection. 
(e)  Ensure  the components  are at  room  temperature 
before  uncapping, 
to prevent  condensation  of 
moisture from  the air that enters. 
(f) Components must  not remain uncapped  for  longer 
than  fifteen minutes. 
In the event of delay,  the caps 
must  be repiaced. 
(g) Receiveddriers must  never  be left  uncapped  as 
they  contain  Silica Gel crystals  which will absorb 
moisture  from the atmosphere. 
A receiveddrier 
left uncapped  must be replaced, and not used. 
(h)  The  compressor shaft must  not be rotated  until  the 
system  is entirely  assembled  and contains 
a charge 
of  refrigerant. 
1  
						

							izl AIR CONDITIONING - L.H. & R.H.  STEERING 
(j) A new  compressor  contains  an inital charge of 
312,s ml (11 UK fluid ozs) of oil  when  received, 
part 
of which  is distributed  throughout  the  system 
when  it has  been  run. The compressor  contains  a 
holding  charge  of gas  when  received  which should 
be retained  until the hoses  are connected. 
(k) The receiveddrier should  be  the last  component 
connected  to the  system  to  ensure  optimum 
dehydration  and  maximum  moisture  protection of 
the  system. 
(I) All  precautions  must be taken  to prevent  damage 
to  fittings  and  connections.  Slight damage  could 
cause  a leak  with  the high  pressures  used 
in the 
system. 
(m)  Always use  two spanners 
of the correct size,  one on 
each  hexagon,  when  releasing  and  tightening 
refrigeration  unions. 
Joints  and 
‘O’ rings  should be coated  with 
refrigeration  oil to aid  correct  seating.  Fittings 
which  are 
not lubricated  with refrigerant  oil are 
almost  certain  to leak. 
All  lines  must  be free  of kinks.  The efficiency 
of 
the  system  is reduced  by a single  kink  or 
restriction. 
Flexible  hoses  should 
not be bent  to a  radius  less 
than ten  times 
the diameter  of the  hoses. 
Flexible  connections  should  not be  within 
50 mm 
(2 ins) of the exhaust  manifold. 
Completed  assemblies must  be checked  for 
refrigeration  lines touching  sheet metal  panels. 
Any  direct  contact  of lines  and  sheet  transmits 
noise  and must 
be eliminated. 
PERIODIC  MAINTENANCE 
Routine servicing  apart from visual  checks,  is not 
necessary. 
The visual  inspections  are as follows: 
Condenser 
With  a hose  pipe or air  line,  clean 
the face of the 
condenser  to remove  flies,  leaves  etc. Check 
the pipe 
connections  for signs of 
oil leakage. 
Compressor 
Check  hose connections  for signs of 
oil leakage. Check 
flexible  hoses  for  swelling. Examine the compressor 
belt 
for tightness  and  condition.  Checking  the 
compressor  oil 
level and  topping-up is only  necessary 
after  charging  the system  or in the  event  of a 
malfunction 
of the  system.  Evaporator 
Examine  the refrigeration  connections  at  the unit. 
If 
the  system  should  develop a fault, or if erratic 
operation  is noticed, refer  to the fault diagnosis  chart. 
Service  valves 
There  are  two types 
of service  valves in operation: 
‘Stem’  and ‘Schrader’. 
To identify where  the  different 
operations  occur, stem  type will be boxed. 
Stem  type 
Stem  type  service valves  allow  for the  isolation 
of the 
compressor  from other  parts ol the system. When these 
valves  are used 
in conjunction  with the liquid line 
quick-disconnect  fittings,  the three  major  assemblies  of 
the  system  can be  removed  from  the vehicle  with a 
minimal 
loss of  refrigerant. In addition, it is possible  to 
remove  major  assemblies for repair  of components 
which  are not  part 
of the refrigeration  system, or 
provide  access to parts  of the  vehicle  which are 
obstructed  by the  air conditioning system,  without fully 
discharging  the  system. 
A thormgh understanding  of 
the  stem  type  service  valve is necessary  before 
undertaking  servicing 
or repair involving  the air 
conditioning  system. 
~-.~ 
4 -- 
4 
5 
4 ‘3 
ST1387M 
Stem type service  valve 
1 Serviceport 
2 Valve stem 
3 Compressor  port 
4 Valve seat 
5 Hose connector 
ReceivedDrier 
Examine  the sight  glass  for  bubbles  with the system 
operating.  Check connections for leakage. 
2