Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							01 
5- 9 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’. 
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 Scrvice, 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  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. 
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  provides basic precautions  which must be observcd 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 
petrol/gasoline evaporates it produces 150 times  its own  volume  in vapour,  which when diluted  with air 
becomes  a readily  ignitable  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. 
3  
						

							Always have a fire extinguisher  containing FOAM CO1 GAS, or POWDER  close at hand  when  handling or draining 
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 head-lamps  used must  be flameproof and kept clear  of >pillage. 
NO ONE  SHOULD  BE PERMITIED 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 
petroUgasoline 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 PETROL/GASOLINE VAPOUR warning label attached to  them 
as  soon  as they  are 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 
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. .e-., $. ., -jl SPECIFICATION 7%yr 
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  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  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. 
i .. ,* 
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							-3 & ,= ..., . . ... .. ~ ..,_.,, . . .. 
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. 
Countties where  there is no distributor  may order  direct from V. L. Churchill  Limited. P.O. 
BOX 3, Daventry,  Northamptonshire,  England 11 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  the following  address, Land  Rover Limited,  Service Department,  Lode Lane, 
Solihull, West Midlands.  England 
B92 8NW. 
5  
						

							L 
01 LOCATION OF VEHICLE IDENTIFICATION  AND UNIT  NUMBERS i 
VEHICLE  IDENTIFICATION  NUMBER (MN) 
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 
C 
D 
E 
F 
VIN (minimum of 17 digits) 
Maximum  permitted laden  weight for vehicle 
Maximum vehicle  and trailer  weight 
Maximum road  weight 
- front axle 
Maximum  road weight 
- rear axle 
;TOO I 
I ST037 I 
ENGINE  SERIAL NUM3ER - V8 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 G- machined  surface at the  front  left-hand  side  of the 5 engine  adjacent  to  the  exhaust manifold  front  flange. %- 
On later engines  the number  is stamped  above the rear 
side  cover,  as the second  illustration  shows. 
..  
						

							I. 
1 
.. ..... 
ST663M 
.. 
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. 
RR 470M 
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.  Stamped 
plate. 
On the right-hand  side of the front  bearing 
ST 1 546M 
7  
						

							GENERAL SPECIFICATION DATA 
... GENERAL  SPECIFICATION  DATA ,?F.,. L:,, -,:: .. .... , ,, . ... 
V8 ENGINE 
ENGINE 
Type ................................................................. 
Number of cylinders ............................................. 
Capacity ............................................................ 
Valve  operation.. ................................................. 
Maximum power - B.H.P.. ................................... 
Maximum power- KW ........................................ 
Maximum  torque ................................................. 
Bore ................................................................. 
Stroke ............................................................... 
V8 
Eight,  two banks 
of four 
88,90 mm (3.500 in) 
71,12 mm (2.800 in) 
3528 cc (215 in3) 
Overhead  by push-rod 
113 } at4000rpm 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 ........................................ Taken  on thrust washers of centre  main bearing 
Crankshaft end
-float .......................................... 0,lO - 0,20 mm (0.004 - 0.008  in) 
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) 
- 
Main  bearings 
Number  and type. ............................................. 5, Vandervell  shells 
Material 
......................................................... Lead-indium 
Diametrical  clearance 
........................................ 0,010 - 0,048 mm (0.0004 - 0.0019 in) 
Undersizes 
...................................................... 0,254 mm, 0,508 mm (0.010 in,  0.020  in) 
Connecting  rods 
Type .............................................................. Horizontally  split big end, plain 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 
...................................................... 0,254 mm, 0,508 mm (0.010 in, 0.020  in) 
Vandervell 
VP lead
-indium 
Gudgeon pins 
Length ........................................................... 72,67 - 72,79 mm (2.861 - 2.866  in) 
22,215 
- 22,22 mm (0.8746 - 0.8749  in) 
Fit
-in  connecting rod ......................................... 
Clearance in piston.. .......................................... 0,002 - 0,007 mm (0.0001 - 0.0003 in) 
Diameter 
........................................................ 
Press fit 
Pistons 
Clearance in bore, 
measured at  bottom of skirt  at 
right angles  to gudgeon  pin 
.................................. 0,018 - 0,033 mm (0.0007 - 0.0013 in) 
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							04 
Piston rings 
Number  of compression 
..................................... 
Number of oil .................................................. 
No. 1 compression  ring ....................................... 
No. 2 compression ring.. ..................................... 
Width of compression  rings ................................. 
Compression  ring gap ........................................ 
Oil ring  type .................................................... 
Oil ring  width ................................................... 
Oil ring  gap ..................................................... 
GENERAL SPECIFICATION DATA 
2 
1 
Chrome  parallel faced 
Stepped  to L  shape  and marked 
T or TOP 
1,56 - 1,59 mm (0.0615 - 0.0625  in) 
0,44 - 0,57 mm (0.017 - 0.022 in) 
Perfect  circle, type 98
-6 
4,811 
mm (0.1894  in) max 
0,38 - 1,40 mm (0.015 - 0.055  in) 
Camshaft  Location 
......................................................... Central 
Bearings 
......................................................... Non-serviceable 
Drive 
............................................................. 
Number  of bearings.. ......................................... 5 
Chain 9,52 mm (0.375  in) pitch x 54 pitches 
Valves  Length:  Inlet 
........................................................... 
Exhaust.. ..................................................... 
Inlet ........................................................... 
Exhaust ....................................................... 
Inlet ........................................................... 
Exhaust.. ..................................................... 
Inlet ........................................................... 
Exhaust ....................................................... 
Inlet ........................................................... 
Exhaust.. ..................................................... 
Seat  angle: 
Head  diameter: 
Stem  diameter: 
Stem 
to guide  clearance: 
Valve 
lift (inlet  and exhaust). ............................... 
Valve  spring  length  fitted .................................... 
116,59 - 117,35 mm (4.590 - 4.620 in) 
116,59 - 117,35 mm (4.590 - 4.620 in) 
45 - 45h 
45 - 45% 
39,75 - 40,00 mm (1 S65 - 1.575 in) 
34,226 
- 34,480 mm (1.3475 - 1.3575  in) 
8,664 
- 8,679 mm (0.3411 - 0.3417 in) 
8,651 - 8,666 mm (0.3406 - 0.3412  in) 
0,025 
- 0,066 mm (0.0010 - 0.0026  in) 
0,038 
- 0,078 mm (0.0015 - 0.0031  in) 
9,49 mm (0.374 in) 
40,4 mm (1.590 in) at pressure  of 293 kg (65 lbs) 
Lubrication  System 
........................................................... Wet  sump,  pressure  fed 
System  pressure,  engine warm at 2400 
rpm ............. 2,l - 2,8 kgf cm2 (30 - 40 Ibf in2) 
Oil filter  (external). ........................................... Full-flow,  self-contained cartridge 
Oil  filter  (internal) 
............................................ Gauze.  Pump intake  filter 
Oil  pump  type 
.................................................. Gear 
Oil pressure  relief valve 
Type 
.............................................................. Non-adjustable 
Relief  valve spring: 
Free  length 
................................................... 81,2 mm (3.200 in) 
Compressed  length at 4,2 
kg (9.3 Ib)  load ............ 45,7 mm (1.800 in) 
Oil  filter  by-pass  valve 
Type 
........................... 1 .................................. Non-adjustable 
By-pass  valve spring: 
Free  length 
................................................... 37,5 mm (1.48  in) 
Compressed  length at 
0,34 kg (0.75 Ib) ................ 22,6 mm (0.89  in) 
2  
						

							GENERAL SPECIFICATION DATA 10411 
I, .n .r ,. 2.25 LITRE PETROL ENGINE 1 .. - . . d :
						

							04 
Piston rings 
Compression ................................................... 2 
Gap  in bore 
.................................................. 0,38 - 030 mm (0.015 - 0.020  in) 
Clearance  in groove 
........................................ 0,046 - 0,097 mm (0.0018 - 0.0038 in) 
Oil control 
...................................................... 1 
Gap  in bore .................................................. 0,38 - 030 mm (0.015 - 0.020  in) 
Clearance  in groove 
........................................ 0,038 - 0,089 mm (0.0015 - 0.0035  in) 
GENERAL SPECIFICATION DATA 
Camshaft 
Location. ........................................................ 
End-float ........................................................ 
Material ......................................................... 
Drive ............................................................. Chain Right
-hand 
side (thrust side)  of engine 
0,06 . 0,13 mm (0.0025 . 0.0055 in) 
Steel shell, white metal  lined 
Number 
of bearings.. ......................................... 4 
Valves 
Length: 
.Inlet 
........................................................... 
Exhaust.. ..................................................... 
Inlet ........................................................... 
Exhaust ....................................................... 
Inlet ........................................................... 
Exhaust ....................................................... 
Inlet ........................................................... 
Exhaust ....................................................... 
Inlet ........................................................... 
Exhaust ....................................................... 
Inlet ........................................................... 
Exhaust.. ..................................................... 
Seat  angle: 
Head  diameter: 
Stem diameter: 
Stem 
to guide clearance: 
Valve 
lift: 
111,20- 111,66mm (4.378-4.396in) 
111,22 - 111,58mm (4.388 - 4.412  in) 
30
 
45 
44,32 - 4437 mm (1.744 - 1.755 in) 
34,93 - 35,18 mm (1.378 - 1.380 in) 
7,899 
- 7,912 mm (0.3109 - 0.3115  in) 
8,682 
- 8,694 mm (0.3418 - 0.3422  in) 
0,033 
- 0,048 mm (0.0013 - 0.0019  in) 
0,058 - 0,073 mm (0.0023 - 0.0029 in) 
10,236 
mm (0.403 in) 
9,85 mm (0.388 in) 
Valve  springs 
Type.. ............................................................ Duplex interference  coil 
Inner:  Length, free 
................................................. 42,67 mm (1.680 in) 
Length, 
under8,O kg (17.7  Ib) load .................... 
Length, free ................................................. 
37,13 mm (1.462  in) 
46,28 mm (1.822 in) 
Outer: 
Length,  under 21 
kg (46 lb) load ........................ 40,30 mm (1.587 in) 
Lubrication 
System ........................................................... 
Type ........................................................... 
Steel gear ..................................................... 
Aluminium  gear ............................................ 
Radial clearance of gears ................................. 
Backlash of gears ........................................... 
System pressure, engine  warm at 2000 rpm ............. 
Oil pump: Early  type 
Drive 
.......................................................... 
End-float of gears: 
.. 
Wet  sump,  pressure fed 
2,45 - 4,50 kgf cm2 (35 - 65 lbf in2) 
Double  gear 
Splined shaft  from camshaft skew  gear 
0,05 - 0,12 mm (0.002 - 0.005 in) 
0,07 - 0,15 mm (0.003 - 0.006 in) 
0,02 - 0,lO mm (0.001 - 0.004 in) 
0,15 - 0,28 mm (0.006 - 0.012  in) 
4