Land Rover Defender 90 110 Workshop 1984 Rover Manual

							RADIATOR ASSEMBLY - TURBO-CHARGED 
VEHICLES. 
Removing 
1. Disconnect  the battery. 
2. Remove the split pin and  clevis  pin securing  the 
lower  end of the  bonnet  stay and 
lift-off the 
bonnet. 
3. Remove  the  three screws  each  side securing  the 
radiator  left
-hand  and right-hand  retaining 
brackets  and remove  the brackets. 
4. Remove the  four screws  and withdraw  the radiator 
cooling 
fan cowl. 
5. Disconnect  the bottom  hose from  the radiator  and 
drain the  coolant. 
6. Disconnect the oil cooler inlet and outlet  pipes 
from  the  radiator  and  blank
-off the  pipes  and 
radiator 
aperturcs to prevent  ingress of dirt. 
7. Disconnect  the radiator  top hose  from  the radiator 
and thermostat housing. 
8. Disconnect  expansion tank  hose from  radiator. 
9. Lift the radiator from the  engine compartment. 
10. If the radiator  is to be renewed,  remove the oil 
cooler  unions  from the radiator  and 
fit to the 
replacement  radiator. 
Fitting 
11. Fit the radiator into  position ensuring that the two 
pegs at the  bottom of the  radiator  locate in the 
corresponding  rubber  pads 
in the cross  member 
brackets. 
1 
ST18GYM 
12. Fit the  radiator  top hose to the radiator  and 
thermostat  housing. 
13. Conncct the radiator bottom  hose. 
14. Fit the expansion tank hosc to radiator. 
15. Fit the  fan cowl  and secure  with the four  screws. 
16. Fit the  radiator  left-hand and right-hand rctaining 
brackets. 
17. Fit the  oil cooler  inlet and outlet  hoses to the 
radiator. 
Hose  A to  top  of radiator. 
Hose 
B to  bottom of radiator. 
18. Fit the  bonnet and  stay securing  with the clevis pin 
and new  split pin. 
CTInCnl JI l0UOlVl 
.,.:..:: . . . *:. .. , 
5  
						

							Filling radiator 25. Connect the battery  and run the engine  until 
normal  running  temperature 
is attained  whilst 
checking  for coolant  leaks. 19. Check that all hose clips are tight. 
20. Remove  the expansion  tank cap. 26. Stop  the engine  and allow  it to cool completely. 
27. Remove  the radiator  plug and check thc level  and 
28. Top-up level  of expansion  tank and fit the cap. 
fit and  tighten  plug. 
21. Remove  the radiator  plug. 
22. Fill the system  with coolant  using a mixture of 
water and anti-freeze or anti-corrosion  inhibitor, 
through  the expansion  tank 
until1 the coolant is just 
below  the level  of the  radiator  plug hole.  Continue 
filling  until the expansion  tank 
is half-full. 
23. Fit the expansion  tank cap and  radiator  plug. 
Tighten  the plug  to 
40- 50 Ibs. in. 
24. Check  the engine oil level  in sump  and top-up. 
6  
						

							D-POOR CIRCULATION 
SYMPTOM 
A-EXTERNAL  LEAKAGE 
B
-INTERNAL  LEAKAGE 
C
-WATER  LOSS 
COOLING SYSTEM FAULT DIAGNOSIS 
POSSIBLE  CAUSE  CURE 
I. Loose hose clips 1. Tighten 2. Defective rubber hose 2. Renew 3. Damagedr a d iator seams 3. Rectify 4. Excessive  wear in the water pump 4. Renew 5. Loose core plugs 5. Renew 6. Damaged gaskets 6. Renew 7. Leaks  at the heater connectionsor  plugs 7. Rectify 8. Leak at the water  temperature gauge 8. Tighten Plug 
I. Defective cylinder head  gasket I. Renew.  Check engine oil for contami- 
2. Cracked cylinder wall 3. Loose cylinder head bolts 3. Tighten.  Check  engine  for oil contam- 
nation and refill  as necessary 
ination and  refill as necessary 
2. Renew cylinder  block 
1. Boiling 1. Ascertain the cause of engine overheat- 
2. Internal  or external leakage 3. Restricted  radiator or inoperative 3. Flush  radiator  or renew  the  thermostat 
ing 
and 
correct as ncccssary 2. See  items  A and B 
thermostat  as necessary 
1. Restriction  in system 
2. Insufficient  coolant 3. Inoperative water pump 4. I.oosc fan belt 5. Inoperative therinostat 
2. Infrequent flushing  and draining of system 
3. Incorrect  anti-freeze  mixtures 
1. Check  hoses  for crimps,  reverse-flush 
the  radiator,  and  clear  the  system of rust 
and  sludge 
2. Replenish 3. Renew 4. Adjust 5. Renew 
1. Use  only  soft,  clean  water  together with 
correct  anti-freeze or inhibitor mixture 2. The cooling  system  should be drained 
and  flushed  thoroughly  at least once a 
year 
3. Certain anti-frecze solutions  have  a  cor- rosive cffect on  parts of the  cooling  sys- tem.  Only rccommcnded solutions 
should be used. 
F-OVEKHEATING 1. Poor  circulation 2. Dirty oil and sludge  in engine 3. Radiator  fins choked  with chaff,  mud. 
etc. 
4. Incorrect  ignition timing 5. Insufficient  coolant 6. Low oil level 7. Tight engine 
8. Choked or damaged exhaust pipe or 
9. Dragging  brakes 
silencer 10. Overloading 
vehicle 1 I. Driving in heavy  sand or mud 12. Enginc labouring on gradients 13. Low gear  work 
14.  Excessive  engine idling 
15. Inaccurate tcmperature gauge 16. Defective  thermostat 
1. 2. 3. 
Sce item D 
Refill 
Use air prcssure from  the  engine  side of the radiator and clean  out passages 
thoroughly 
4. Check  using electronic equipment 5. SeeitcmD 6. Rcplenish 7. New  engines  arc very  tight  during the 
running-in  period  and  moderate  speeds 
should  be maintained  for  the first 1,000 miles (1500 km) 8. Rectify  or renew 
9. Adjust  brakes 10. In the hands of the operator 11. In thc hands of the operator 12. In the hands of  the operator 13. In the  hands of the operator 14. In the hands of the operator 15. Renew 16. Rcnew 
G-OVEKCWOLING 1. Defective  thermostat 2. Inaccurate temperature  gauge I. Renew 2. Renew 
T 
7  
						

							.  
						

							CLUTCH 
. ’ ..::;:. ... _...... , OVERHAUL RELEASE BEARING ASSEMBLY ...., ... i.. . . ., .. , !9!: 
I. Remove the clutch slave cylinder  from the bell 
2. Withdraw the retaining  staple, if fitted. 
3. Remove the release  bearing  assembly. 
4. Remove  spring clip retaining  bolt and spring- V8. 
5. Remove  the slipper  pads - 4-cylinder  engines 
6. Withdraw  the relcase lever. 
7. Discard worn parts. 
8.  Smear  the pivot 
with grease  and fit the release 
lever  and retain  with the spring  clip and  bolt 
- V8. 
9. Smear  the release  bearing  sleeve inner diameter 
with Molybdenum  disulphide base grease. 
housing. 
only. 
10. Fit 
the  slipper  pads. 
11. Fit the release bearing assembly  and retain  with the 
staple.  The staple  is to  aid  assembly  and has no 
other  purpose.  It may  become  dislodged 
in service, 
. .. without detriment. .. , . 
33 
Illustration A. V8 engine 
ST1134M ,,’ i 7 
Illustration B. 4-cylinder  engines 
B 
3 
, ‘ -. L. 
ST1135M 
12. Coat both sides of the backing  plate with a 
waterproof  joint compound  such as Hylomar 
PL32M and  locate  the backing  plate and dust  cover 
in  position  on 
the slave cylinder. 
13. Check  that the push-rod  clip is in position. 
14. 
Fit the  slave  cylinder,  engaging the push-rod 
through  the centre 
of the  dust  cover  and with the 
bleed  screw  uppermost.  Secure the cylinder  with 
the  two  bolts,  tightening 
cvenly to the  correct 
torque. 
OVERHAUL  MASTER CYLINDER - All models 
DISMANTLE 
1. Remove the master  cylinder  from the vehicle. 
2. Remove  the circlip. 
3. Withdraw  the push-rod  and  retaining  washer. 
ST1136M 
4. Withdraw  the piston  assembly. If neccssary,  apply 
a low air pressure to the outlct port  to expel  the 
piston. 
continucd 
STl137M 
1  
						

							(33) CLUTCH 
5. Prise the locking  prong of the  spring  retainer  clear 
of the piston  shoulder and  withdraw the piston. 
6. Withdraw the piston seal. 
7. Compress the spring and position  the valve  stem to 
align with 
the larger hole in  the  spring  retainer. 
8. Withdraw the spring and  retainer. 
9. Withdraw the valve  spacer and  spring washer  from 
the  valve  stem. 
10. Remove  the valvc seal. 
ST1139M 
Inspection 
Assemble 
14. 
Smear the seals with  Castrol-Girling  rubber grease 
and 
the remaining  internal  items with Castrol- 
Girling  brake and clutch  fluid. 
15. Fit the valve  seal, flat side  first,  onto the  end of the 
valve  stem. 
16. Place  the spring washer,  domed side first,  over the 
small end of the  valve  stem. 
17. Fit the spacer,  legs first. 
15 
STl140M J 
18. Place the coil spring  over the valve stem. 
19. Inscrt the retainer  into the spring. 
20. Compress  the spring  and  engage thc valve  stem in 
the keyhole  slot in the retainer. 
ST1141M 
11. Clean  all components in Girling  cleaning  fluid and 
allow  to dry. 
12. Examine  the  cylinder  bore and  piston,  ensure that 
they  are  smooth  to the  touch  with 
no corrosion, 
score marks 
or ridges. If there  is any  doubt.  fit  new 
21. Fit the seal,  large diameter  last, to the  piston. 
22. Insert  the piston  into the spring  retainer  and - replacements.  engage  the locking  prong. c- 
13. The seals  should  be replaced  with  new i .I 3 
components. continued 
2  
						

							CLUTCH 
OVERHAUL SLAVE CYLINDER 
DISM ANTL,E 
1. Remove the slave  cylinder  from the vehicle. 
2. Withdraw the dust cover. 
3.  Expel  the  piston assembly,  applying low pressure 
4. Withdraw the  spring. 
5. Prise off the seal  from the piston. 
air 
to the 
fluid inlet. 
STl142M 
23.  Smear the piston  with  Castrol-Girling rubber 
grease  and insert  the assembly,  valve end first,  into 
* the cylinder. 
24.  Fit the push
-rod,  retaining  washer and circlip. 
ST1144M 
ST1143M 
BLEED  CLUTCH  HYDRAULIC SYSTEM 
When the gearbox and bcll housing assembly  has  been 
fitted  to the  vehicle 
the hydraulic  clutch release  system 
must  be bled  to expel  air. 
NOTE:  During  the  following  procedure,  keep  the fluid 
reservoir  topped
-up  to avoid  introducing  air  into  the 
system.  Use only  the  fluid  recommended  in the 
Lubrication  chart. 
Use only  new fluid  from a sealed  Inspection 
6. Clean all components 
with Girling  cleaning  fluid 
and  allow  to dry. 
7. Examine  the cylinder  bore  and  piston,  ensure  that 
they are smooth to the touch  with no  corrosion, 
score marks 
or ridges.  If there  is any  doubt, fit ncw 
replacement. 
8. The  seal  should  be replaced  with a new 
com pon e n t . 
Assemble 
9. Smear the seal  with  Castrol-Girling  rubber grease 
and  the remaining  internal  items  with Castrol
- 
Girling  brake and clutch  fluid. 
10. Fit the  seal, largc diameter last,  to the  piston. 
11. Locate  the conical  spring, small diameter  first, over 
the front end of the piston. 
12. Smear  the piston, with Castrol-Girling  rubber 
grease  and  insert 
the assembly,  spring  end  first, 
, container. into the cylinder. 
1. Attach a length of suitable tubing to the slave 13. Fill the dust Cover with Castrol-Girling  rubber 
cylinder  bleed  screw  and immerse 
the free  end of the  grease 
and fit the cover  to the  cylinder. 
tube 
in a glass jar  containing  new clutch fluid. 
2. Slacken  the  bleed  screw  and  depress  the  clutch 
pedal,  pausing  at the  end 
of each  stroke, until the 
fluid  issuing 
from the  tubing  is free  of air with the 
tube  free end  below the surface 
of the fluid in the 
container.  Whilst holding  the clutch  pedal down and 
with  the free  end 
of the tube  below the fluid, tighten 
the  bleed  screw. 
*, . . 
3  
						

							CLUTCH PEDAL AND MASTER  CYLINDER 
ADJUSTMENT 
1. The correct  height for the  clutch pedaI from the 
floor of the footwell,  without a mat,  to  the  lower 
edge 
of the  pedal is 140 mm (5.5 in),  dimension 
A. 
Adjust 
2. Withdraw the  six screws  and remove  the top  plate. 
3. Slacken  master  cylinder  push-rod  locknuts to 
provide free movement of the push-rod  through 
the pedal  trunnion. 
4. Slacken the adjustment  screw locknut. 
5. To increase  the pedal  height,  turn  the adjustment 
screw  anti
-clockwise.  To reduce  turn clockwise. 
When  correct tighten  the locknut. 
6. To adjust the master  cylinder push-rod, check  that 

						

							Section - .- .  L .I. y;. Number I.. 
37 
CONTENTS 
LT230R TRANSFER GEARBOX 
Page 
* 
LT77 FIVE SPEED  GEARBOX 
J 
37 LT95 FOUR SPEED  GEARBOX  AND TRANSFER BOX 
37 
- Overhaul 
Renew  front output  shaft 
oil seals 1 can be 
LTWLT230T MAIN GEARBOX  AND TRANSFER  BOX 
20 
18 
51 REAR DIFFERENTIAL - NINETY HEAVY DUTY 
- Remove  61 
- Overhaul LT85 gearbox 62 
37 I LT230T TRANSFER GEARBOX 
L 
51 
- Remove from LT85 gearbox 
- Overhaul 
REAR DIFFERENTIAL - NINETY 
147 I PROPELLER SHAFTS 
86 
91 
-Overhaul 
FRONT DIFFERENTIAL - ONE TEN AND  NINETY 
16 
-Overhaul 16 
I  
						

							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 
thc Repair Operation  Times. 
The  Manual  has been  produced 
in separate  books;  this allows  the information  to be  distributed  throughout  the 
specialist 
arcas of  the modern  service facility. 
A  table 
of contents in Book 1 lists  the major components  and systems  together  with the scction and book  numbers. 
The  cover  of each book  details the sections  contained  within that book.  Each section  starts with a list  of operations 
in 
alphabetical  order. 
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  rcmovcd, the  water pump  end of the 
enginc is referred to as the  front. 
To  reduce repetition,  operations covcrcd 
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 * (7: 
particularly  where safety  related items are conccrned. -2s 
DIMENSIONS 
The dimensions  quoted are to design  engineering  spccification.  Alternative unit equivalents, shown in brackets 
following  the dimensions, havc 
bccn converted from  the original  specification. 
During 
thc pcriod of running-in  from  new, ccrtain adjustments  may vary  from the specification figurcs given in this 
Manual.  These  adjustments  will be re
-set  by the Distributor or Dealer  at thc Aftcr Sales Service, and thercalter 
should  be maintained at the figures spccified 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 
rcpairs 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 vehiclc manufacturers  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 havc the full backing  of the  Owners  Service Statement. 
Land  Rover  Distributors  and Dealers are  obliged to supply only  Land Rover  service  parts. 
g?- .. . --- 
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 
This  information  is issued  for basic  guidance only,  and 
in any case  of doubt appropriate  enquiries should be made of 
your local  Fire Officer. 
safe!y. It 2!so oll!!iReS !he ather are2s of risk which mut not be ignored. 
GENERAL 
Petrol/gasoline vapour IS highly  flammable  and in confined spaces  is also  very  explosive and toxic. 
When 
petroVgasoline 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. 
II