Land Rover Defender 90 110 Workshop 1984 Rover Manual

							MAINTENANCE 
GENERAL MAINTENANCE  AND ADJUSTMENT 
This second  part of the  maintenance  section  covers 
adjustments  and items  of general  maintenance 
as 
dictated by the  ‘Maintenance  Schedules’. However, 
only maintenance  operations that are not  included in 
the  Overhaul  Sections  of the  manual  appear in this 
section. 
EXAMINE AND  RENEW FRONT BRAKE FRICTION 
PADS 
Examine the friction  pads for wear  and if less  than 
3 mm (0.125 in) thick  or oil contaminated,  they  must 
be  renewed 
on both  wheels  at  the same time,  as 
follows: 
NOTE:  See Book 4 Section 70 for latest  method of 
friction pad retension. 
. l.+Slackcn both  front  wheel nuts and jack-up  the 
vehicle  and  lower  onto axle stands,  and  remove 
whecls. 
2.  Clean  the exterior of the calipers. 
3. Remove the  split pins from the brake  caliper. 
4. Remove the retaining  springs. 
5. Withdraw the friction  pads. 
6. Clean the exposed  parts of the  pistons,  using  only 
new  brake fluid. 
7.  Using piston  clamp 186672  press each piston 
back 
into its bore,  whilst  ensuring  that  the  displaced 
brake  fluid does  not overflow  from the reservoir. 
8. Smear the  faces of the pistons  with Lockheed disc 
brake  lubricant  taking 
care not to !et any reach the 
lining  material. 
9. Insert  the new  friction pads. 
10. Place the friction  pad  retaining springs in position 
11. Apply the footbrake  several times to locate  the 
12. Check the  fluid reservoir  and top-up if necessary. 
8 
and fit new  split  pins and  splay the ends. 
pads. 
13. Fit  the  road  wheels,  lower the vehicle  and finally 
tighten  the wheel  retaining  nuts. 
CLEAN  AND CHECK AXLE BREATHERS - ball 
valve  type 
(where fitted) 
1. Clcan the outside  of the  breather  and unscrew  from 
the  axle  tube. 
2. Wash  the  breather  in petrol  and shake to ensure 
that the  ball valve  is free. 
3. Lubricate  the  ball  with engine oil and  refit  to axle 
tube. 
I 
Remote  axle breathers -where  fitted 
Pipes  attached to the  breathers 
on the  axles  terminate 
at pifits iiiside the chassis members oil eariy muueis 
and into the  engine compartment on later vehicles.  This 
allows  the axles 
to breath  whilst the vehicle is traversing 
mud  and water. 
No maintenance  is required  except to 
ensure that  the  pipe: do not  become  blocked, kinked, 
or  split,  or damaged  in any  other  way to prevent  proper 
breathing. 
,I  
						

							T 
CHECK STEERING BALL JOINTS 
Ball joints  are lubricated  for  the normal  life of ball 
joints  during  manufacture  and  require no further 
lubrication.  This  applies 
only if the  rubber  gaiter  has 
not  become  dislodged  or damaged.  The joints  should 
be  checked  at the  specified  mileage intervals  but  more 
frequently  if the  vehicle  is used  under  arduous 
conditions. 
1. Check  for wear  in the  joints  by moving  the ball 
joint  up and  down  vigorously.  If free  movement  is 
apparent  renew the complete  joint assembly. 
; ST 926M 
I 
CHECK FRONT WHEEL  ALIGNMENT 
Use recognised wheel  alignment  equipment to perform 
this  check  and  adjustment.  See General  Specification 
and  Data  section  for the correct  alignment.  Check  and 
adjust  with the vehicle  on level  ground. 
1. Set the  road  wheels to the straight  ahead position 
and  push  the vehicle  forward a short distance. 
2. Slacken  the  clamp  bolts securing  the ball  joints  at 
both ends  of the  track  rod. 
3. Twist  the track-rod  to decrease  or increase  its 
effective  length  as required  to  achieve  the  correct 
alignment. 
4. Push  the vehicle  rearwards  whilst  moving  the 
steering  wheel  from  side to side 
to settle  the  ball 
joints.  Then with the wheels 
in the straight  ahead 
position  push the vehicle  forward  a short  distance 
and  recheck  the 
alignmcnt. If necessary  make 
further  adjustments.  When the alignment  is correct 
tighten  the ball  joint  clamp  bolts. 
The ball joint  pins  must  be central  in their housing 
and  not inclined 
to one side.  See section 57. 
.- 
ADJUST  REAR BRAKES 
Land Rover One  Ten Vehicles 
1. Raise  up vehicle  and lower onto axle stands. 
2. Each  shoe is independently  set by means  of a 
hexagon  adjuster.  Check that  the  wheel turns 
freely  and turn  one adjuster  until the shoe  is locked 
against  the drum.  Slacken 
off the  adjuster 
sufficiently  for  the wheel  to  turn  freely 
- 
approximately two  serrations on the snail cam. 
3. Repeat  the  above procedure  for the  second  brake 
shoe and the opposite  wheel. 
4. Remove the axle  stands  and road  test the vehicle 
brakes. 
s-r 
Land Rover Ninety Vehicles 
The  shoes  are set by a single  hexagon  adjustment bolt 
operating  through  a  serrated snail cam enabling  both 
shoes  to be  adjusted  to obtain  the best  results. 
1. Raise-up the  vehicle  on to axle stands. 
2. Check that the wheel  rotates  freely then turn the 
adjuster  until the brake  shoes are in  firm  contact 
with  the drum. 
3. Slacken off the  adjuster  just  sufficiently  for the 
drum  to rotate  freely. 
4. Repeat the  procedure for the other  wheel. 
5. Remove  the axle  stands  and road  test the vehicle. 
9  
						

							MAINTENANCE 
AD JUST TRANSMISSION BRAKE (Handbrake) 6. Fit the  clevis pin, washer  and a NEW  split pin. 
1. 
2. 
3. 
.. 7. Slacken  the adjuster 1 or 2 notches until handbrake 
shoes just  clear the drum. 
8. Apply  the  handbrake  gradually. The drum  should 
still  rotate 
on the first  ratchet  and start  to come on 
at the  second  ratchet. 
Set  the 
vehicle 
on level ground  and  chock the 
wheels.  Release 
the handbrake  fully. 
Remove 
the clevis  pin  connecting  the  handbrake 
lever to  the relay  at the  gearbox end. 
CAUTION: DO NOT over  adjust  the handbrake,  the 
drum  must  be free  to  rotate  when  the  handbrake 
is 
released, otherwise serious damage will result. \ \ \M 
DRAIN FLYWHEEL HOUSING 
1. The  flywheel  housing  can  be completely scaled to 
exclude  mud and  water  under severe  wading 
conditions,  by means 
of a plug fitted in  the  bottom 
of the housing. 
2. The  plug  should  only be  fitted  when  the  vehicle is 
expected 
to do  wading  or very  muddy  work. 
3. When  the plug  is in  use it must be removed 
periodically  and all 
oil allowed  to drain  off before 
the plug  is replaccd 
L- i 
4. Turn  the adjuster on the back  plate  clockwise  until 
the  shoes  are fully  expanded  against the drum, 
Illustration 
A. 4-cylinder vehicles. 
if- F &/ 
Illustration B. V8 vehicles. 5. Adjust the outer sheath  of the handbrake  cable by 
means  of the two 
locknuts at the gearbox  end until 
the  holes 
in the clevis on the inner  cable  line up 
with  the hole  in the  relay  lever. 
ST1074M 
4. When  plug is not in use it  should  be stowed as 
follows: 
4 cylinder  models - in tool kit 
V8 - screwed  into housing  near drain hole. ST 1012M 
10  
						

							MAINTENANCE 1101 
DRAIN ENGINE TIMING  COVER - 2.5 Diesel only --h. I ^ Le I *.: 
1. The timing  cover can be completely  sealed to 
exclude mud and water  under  severe  wading 
conditions,  by fitting  a plug 
in the drain hole  at the 
bottom  of the  cover. 
2. The  plug  should  only  be  fitted  when the vehicle  is 
expected 
to do  wading  or very  muddy  work. 
3. When  the plug is in use it must  be  removed 
periodically  and any 
oil present allowed to drain off 
before the  plug is replaced. 
NOTE:  There should  not be any oil in the  timing 
cover,  but if there  is, the  cause  should  be 
investigated 
as soon  as possible, as the  timing  belt 
will  deteriorate  if it  becomes  contaminated  with oil. 
4. When  the  plug is not  in  use  it  should be stowed  in 
the  tapped  hole adjacent 
to the drain hole. 
- 
CLEAN  ENGINE  TIMING  COVER FILTER - 2.5 
Diesel only 
A gauze  filter  is fitted  at  the  bottom of the engine 
timing cover  to  help  prevent  mud and other  debris 
entering  the drain  hole, when  the  wading plug is not 
in 
use.  The  filter  must  be  removed and  cleaned 
periodically,  to ensure that  it does  not become  blocked 
and  prevent 
the timing  cover draining  properly.  Under 
normal  circumstances,  the filter  should  be  cleaned  at 
the  intervals  specified  in the  Maintenance Schedule  or, 
more frequently 
if the  vehicle operates  regularly in wet 
or  dusty conditions. 
1. From  underneath  the  vehicle, remove the four 
bolts  and plain  washers  and, withdraw  the wading 
plug  plate from the bottom 
of the timing  cover. 
2. Wash the filter in kerosene  or clean  fuel. Brush  off 
any  mud  or other  debris 
aiid ensure that the whole 
filter 
is quite clean. 
3. Check the condition of the  gasket  for  the wading 
plug  plate.  If necessary, 
fit a new  gasket. 
4. Refit  the wading  plug  plate.  Tighten  the securing 
bolts. 
, I.:. , .I. .. . ,:. . . 
::,::;,, _. . ., : ) 
1 
ST209 
RENEW  AIR CLEANER ELEMENT - 2.5 Diesel  and 
2.25 Petrol engines 
1. Disconnect  the air cleaner hose. 
2. Pull  up  the three  clips and lift out the air  cleaner 
canister. 
3. Unscrew  element wing nut and  sealing  washer. 
4. Remove  and discard  the element. DO NOT 
attempt  to  clean the element, 
fit a new  one during 
reassembly. 
5. Clean  interior  of canister. 
6. Fit  a new  element  and sealing  washer. 
ST206 
continued 
11  
						

							MAINTENANCE 
Check air cleaner  dump valve 
The dump  valve provides  an automatic  drain for the  air 
cleaner  and is fitted  in the  base  of the  air cleaner 
support  bracket. 
7. Squeeze  open the dump  valve and check  that the 
interior  is clean. 
Also check  that the rubber  is 
flexible  and in a good  condition. 
8. If necessary,  remove the dump  valve to clean  the 
interior.  Fit 
a new valve  if the  original is in a poor 
condition. 
Fit  air cleaner 
9. Fir  air cleaner  canister  and secure  with the clips. 
10. Connect  the air cleaner  hose. 
RENEW AIR CLEANER ELEMENT - VS engine 
1. Unscrew  the two  air cleaner  strap retaining  nuts. 
2. Disconnect  the air cleaner  hose. 
3. Remove  the engine  breather  hose. 
4. Withdraw  air cleaner  canister. 
5. Unscrew  element wing nut and  washer  and remove 
filter  seal. 
6. Remove  and discard  the element. DO NOT 
attempt  to clean  the element,  fit a new  one during 
reassembly  and secure  with the wing  nut. 
Check  air cleaner  dump valve 
7. Squeeze  open the dump  valve and check  that the 
interior  is clean. 
Also check  that the rubber  is 
flexible  and in a good  condition. - 
8. If necessary,  remove the dump  valve to clean  the t . ;, 
interior. Fit a new  valve if the original  is in  a poor 
condition. 
Fit  air  cleaner 
9. Fit a new  element  and reassemble  the air cleaner. 
10. Fit  the  air cleaner  canister. 
11. Fit the  breather  hose. 
12. Fit the  air cleaner  hose. 
13. Secure with the retaining  straps and nuts. 
CLEAN  FUEL LIFT PUMP SEDIMENT BOWL - 
Petrol engine - early vehicles 
1. Remove  the bowl  by slackening  the thumb  screw 
2. Remove  and clean  the filter gauze  in clean  petrol. r; 3. Ensure  that the sealing  washer  is in  good  condition. .s/ 
4. Replace  gauze and refit  the bowl. 
5. Prime  the pump  by operating  the hand  lever. 
and 
swinging  the retainer 
to one  side. 
ST1068M 
12  
						

							/- 7 -> ?!! :?: 3 CLEAN ELECTRIC F’UEL PUMP FILTER - V8 and 
later 
2.25 Petrol  engine  vehicles 
The pump is located  mid-way along  the right  hand side 
of the chassis. 
1. Release  the three  bolts  and  remove the  protective 
cover 
- except  ‘90’ models. 
1 ST 1014M 
2. From  beneath  the vehicle  disconnect  the fuel  inlet 
pipe 
from the  pump  and blank  the end  of the  pipe 
by  suitable  means to prevent  fuel draining  from the 
tank. 
3. Release  the end  cover  from the bayonet  fixing. 
4. Withdraw  the  filter  and  clean by using  a 
compressed air 
jet from  the inside  of the  filter. 
5. Remove  the  magnet  (where  fitted)  from  the end 
cover  and clean.  Replace  the magnet  in the  centre 
of  the end  cover. 
6. Reassemble  the fuel  pump  and refit  the fuel  inlet 
pipe. 
7. Use  a new  gasket  for the  end  cover if necessary. 
8. Fit the  protective cover. 
r. 
RENEW FUEL FILTER  ELEMENT - Petrol engines 
4
-cylinder  and V8 
The element  provides  a  filter between  the  pump  and 
carburetter and 
is located  adjacent to fuel pump  on the 
right  hand  side of the  chassis. 
1. Release  the three  bolts and remove  the protective 
2. Unscrew the centre  bolt. 
3. Withdraw the filter  bowl. 
4. Remove the  small  sealing ring and remove  the 
element. 
5. Withdraw  the large  sealing  ring from  the underside 
of  the filter  body. 
6. Discard the old  element  and  replace  with a new 
unit. 
7. Ensure  that the centre and  top sealing  rings are in 
good condition and replace  as necessary. 
8. Fit new  element,  small hole downwards. 
9.  Refit  sealing  rings (small  and large). 
cover. 
See ‘Clean  electric fuel pump  filter’. 
10.  Replace filter  bowl and tighten 
the centre bolt. 
ST1075M kG2 
‘ 
12 
13  
						

							10 
RENEW FUEL FILTER ELEMENT - Diesel engines 
Drain 
off Water  FUEL 
SEDIMENTER 
- Diesel engines (where fitted) 
The sedimenter  increases the working  life of the fuel 
filter  by removing  the larger  droplets  of water  and 
larger  particles  of foreign  matter from the fuel. 
Drain off water as follows: 
1. Slacken  off drain  plug to allow  water  to run  out. 
2. When  pure diesel  fuel is emitted,  tighten drain 
Plug
- 
MAINTENANCE 
- 
ST062 
Renew filter 
3. Support element holder. 
4. Unscrew thc special  bolt  on top  of  the  filter,  the 
element holder  can now be removed. 
5. Remove and  discard the used  element. 
6. Wash the element holder  in petrol  or fuel  oil. 
7. If necessary  renew both the large  rubber  washer 
and  the small  rubber  washer  in the  filter  top, also 
renew  the  large  rubber washer  in the  element 
holder. 
8. Push  the  new elcment onto the filter  top spigot 
with  the holes  in the element 
to the  top. 
9. Fit  the  element  holder to the  bottom  of the 
element,  and secure  with the special  bolt. 
10. Prime the system and check for  fuel leaks. 
14 
Drain off Water 
1. Slacken  off drain  plug to allow water  to run  out. 
2. When  pure diesel  fuel is emitted,  tighten  drain 
plug.  Dismantle and  clean as detailed  below. 
1 
-/ ST 101 7M 
Clean element 
3. Disconnect  fuel  inlet  pipe  at sedimenter  and raise 
pipe  above  level of fuel  tank  to prevent  draining 
from  tank.  Support  in this 
positon. 
4. Support sedimenter  bowl and unscrew  bolt on  top 
of  unit  and remove  bowl. 
5. Remove the sedimenter element. 
6. Clean all parts  in kerosene. 
7. Fit  new  seals and reverse removal  procedure. 
8. Slacken off the  drain  plug, when  pure diesel  fuel 
9. If necessary, prime  the system. 
runs 
out tighten  plug. Cu” 
10. Start engine  and chcck for leaks  from sedimenter. 
ST 1018M 
w4  
						

							MAINTENANCE 
I . * RENEW DUCELLIER  DISTRIBUTOR POINTS - :, I ,>,4 c. < 4-cylinder engines 
Renew  Points 
1. Release  the spring  clips and remove  the distributor 
cap. 
2. Pull  off the rotor  arm. 
3. Remove the  dust shield. 
4. Remove the retaining  screw and remove  the fixed 
5. Slide the spring  clip rearwards. 
6. Disconnect  the suppressor  lead from  the connector 
7. Disconnect the lead from  ignition  coil. 
8. Remove  insulation  washer from the moving 
contact point. 
9. Lift  off the  moving  contact point complete  with 
leads  and connector  block from the distributor 
body.  contact point. 
block. 
T 10: Fit 
the  new  moving  point over post. 
11. Locate the  leaf spring  in the plastic  guide. 
12. Fit the  insulation  washer. 
13. Secure the  assembly with the spring clip. 
14. Fit the  connector  block to the  distributor  body. 
15. Connect ignition coil  lead. 
16. Fit suppressor  lead to connector  block. 
17. Fit the  fixed  contact  point  and  loosely retain with 
the  screw. 
- 
Adjust  points 
NOTE: The following  two instructions  describe the 
adjustment 
of the  contact  points. The accompanying 
illustration  shows it being  done with the aid 
of special 
tool 
18G1308. Whilst  the points  can be adjusted  to the 
datum  setting  only (see data)  without  the tool  full 
distributor  adjustment,  i.e. dwell  angle,  dwell variation 
and  vacuum  advance  can only  be achieved  by using  this 
tool  in conjunction  with engine  diagnostic  equipment.  It 
is  essential  that the above  adjustments  are carried  out in 
order to maintain  correct emission  levels and maximum 
engine  efficiency. 
18. Rotate  the engine  until a cam of the  rotor  fully 
opens the  points. 
19. Using  a feeler, adjust the position  of the  fixed 
contact  point  to the  datum  setting and tighten  the 
retaining  screw. 
20. Check and adjust  the  dwell angle,  dwell variation 
and  vacuum  advance. 
15  
						

							El MAINTENANCE 
ADJUST DUCELLIER DISTRIBUTOR - 4-cylinder 
Petrol  engine 
Service 
tool: 
1861308 
Check  and Adjust  Dwell Angle 
NOTE: The following  six instructions  can only  be 
carried  out using  engine  diagnostic  equipment  and 
special 
tool 18G1308. 
1. Start  the engine,  disconnect  the vacuum  pipe from 
the  vacuum  unit and with  the engine  idling check 
the  dwell  angle 
- see  data.  If adjustment  is 
required  stop  the engine,  remove  the  distributor 
cap,  rotor  arm  and  dust cover,  slacken  the fixed 
contact retaining screw  and using  the eccentric
-post 
end  of the  special  tool, as illustrated,  make  an 
appropriate  adjustment.  Tighten the  retaining 
screw,  reassemble  the distributor  and  recheck the 
dwell  angle. 
Check  and adjust  dwell variation 
NOTE: A dwell variation  outside the accepted  tolerance 
- see data - can  be caused  by a mechanical  fault or 
wear within  the distributor. This may  be checked  as 
follows: 
2. Disconnect  the vacuum  advance,  start  the  engine 
and  increase  the speed  to 
2000 r.p.m. A variation 
outside  the  tolerance given in data  indicates  that 
the  distributor  has a mechanical  fault which  cannot 
be rectified  by adjustment. 
-I 7. !f the k’aiiatioi; is acceptabk, reconnect the 
vacuum  pipe, start the engine  and  increase the 
engine  speed to 
2,000 r.p.m. and  release  the 
throttle. Check the dwell  variation  and if necessary 
adjust  by tuming  the eccentric 
‘D’ post  with  the 
special tool  (female 
‘D’ end). Setting  the dwell  for 
minimvin variation  may alter  the basic  setting  and 
this 
must be rechecked  at idle  speed. 
16 
Check  vacuum  advance 
NOTE: If the vacuum  unit has been  removed or the 
distributor  dismantled,  the vacuum  advance  must be 
checked  and 
if necessary  adjusted. 
4. Disconnect  the vacuum pipe  and connect a vacuum 
pump 
to the  unit. 
5. Start  and run  the engine  at idle  speed  and  using a 
timing  light, slowly  increase  the vacuum  and  note 
the  point  at which  vacuum  advance  starts and 
compare  the figure with  that given  in data. 
6. Adjustment of the  serrated  cam, with the special 
tool,  one  tooth  at a  time,  will alter  the point  at 
which  vacuum advance  starts. 
Ft 
6  
						

							MAINTENANCE 1101 
RENEW LUCAS CONTACT  BREAKER SLIDING 
CONTACTS 
- 4-cylinder  petrol engine 
The  contact  set should  be renewed  every 40.000 
km 
(25,000 miles). 
Remove  the old  contacts 
1. Remove  the distributor cap. 
2. Remove the rotor  arm. 
3. Remove the retaining screw and lift the  contact set 
4. Press  the contact  set  spring and release  the 
complete 
from the plate. 
terminal  plate and leads  from the spring. 
Fit 
new contacts 
5. 
6. 
7. 
8. 
9. 
10. 
Clean  the points  with  petrol  to remove  the 
protective coating.  Press  the contact  spring  and  fit the  terminal  plate 
with  the black  lead uppermost. 
Fit  the  contact  set to the  moving  plate, ensuring 
that  the  peg, underneath  the contact  pivot, locates 
in  the  hole  in the  moving plate. 
The  sliding  contact  actuating  fork must  also locate 
over the  fixed peg. 
Loosely  secure the assembly  with the 
scrcw, plain 
and  spring washer. 
Check  that the  contact leaf spring locates  properly 
in  the  insulation  shoe.  Adjust 
gap 
11. 
12. 
13. 
14. 
Rotate  the crankshaft  until  the contact  heel is on 
the  highest  point 
of a cam. 
Adjust  the  gap  by inserting  a  screwdriver  blade 
between  the 
‘V’ shaped notch and pip  and twist  the 
screwdriver. 
Insert  a 
0,35 to 0,40 mm (0.014  to 0.016 in) feeler 
gauge  between  the points  and adjust  to a sliding  fit 
and tighten  the retaining screw. 
Fit  the  rotor  arm. 
ST1082M 
RENEW  DISTRIBUTOR  CONTACT SET - V8 engine 
Fixed  contact  type 
1. 
2. 
3. 
4. 
5. 
6. 
Unclip and remove  the distributor cap. 
Withdraw  the rotor arm. 
Remove  the contact  breaker  spring anchor  nut and 
lift off: 
(a)  the top
-half of insulation  bush 
(b)  the low  tension  lead  (black) 
(c)  the capacitor lead  (orange) 
Remove 
the contact  breaker  retaining screw,  plain 
and  spring  washer  and remove  contact  set 
assembly. 
Remove  the complete  insulation bush. 
Fit  the  contact  breaker  set ensuring  that the 
small 
post  protruding  from below  the contact  set locates 
through the  hole in the  cover plate  into the hole  in 
the  end  of the  vacuum  unit actuating  lever, secure 
with  the screw,  plain and spring  washers. 
continued 
17