Land Rover Defender 90 110 Workshop 1984 Rover Manual

							MAINTENANCE 
7. Assemble the contact  breaker  spring  insulating 
bushes  and electrical  leads, as illustrated, 
in the 
following  sequence: 
(a)  lower  bush 
(b)  spring 
(c) 
low tension lead 
(d)  capacitor lead 
(e)  top bush 
and  secure  with the anchor  spring nut. 
cam  lubrication  pad. 
8. Apply a few  drops  of engine  oil to the  distributor 
Sliding  contact type 
RR090 
3,lO- 3 
Adjust points -both types 
9. Turn the engine  in the  direction  of rotation  until 
the  contacts  are fully  open  or the  heel  of the 
contact  set is on the  highest  point of the  cam. 
10. Using  a  feeler gauge  and  the dwell  angle adjuster 
on the side of the  distributor,  set the  points  to a 
nominal  gap of 
0,35 to 0,40 mm (0.014 to 0.016 in). 
11. At the earliest  opportunity  check and  adjust  the 
dwell  angle 
- see  data - using spccial turning 
equipment. 
12. Fit  the  rotor  arm  and  distributor  cap ensuring  that 
the 
H.T. pick-up brush  moves  freely. 
I -- *. 1 L .. -.. 0 1. Release the clips  and remove  the distributor  cap. 
2. Remove the rotor  arm from the cam  spindle. 
3. Remove  the  retaining  screw and washers  and lift 
the  complete  contact  breaker  assembly from 
the 
moveable  plate. 
4. Remove the nut  and  plastic bushes  from  the 
terminal  post 
to release the leads  and spring. 
5. Discard the old contact breaker  assembly. 
6. Clean the new  points  with  petrol to remove  the 
7. Connect  the leads  to the  terminal  post in the 
protective coating. 
following  sequence: 
(b) red lead  tab 
(c)  contact  breaker  spring eye 
(d)  black  lead tab 
(e)  upper  plastic  bush 
(f) retaining  nut. 
the two  pegs locate  in the  holes. 
(a)  lower 
plastic bush 
ST1083M 
8. Fit the contact  set to the moving  plate ensuring  that 
1s  
						

							MAINTENANCE I 10 I 
;::;., CLEAN AND LUBRICATE V8 ENGINE 
y? DISTRIBUTOR 
Fixed 
contact type 
1. Remove distributor  cap. 
2. Remove rotor arm. 
3. Lightly  smear the cam  with  clean  engine  oil. 
4. Add a few  drops  of thin  machine  oil to lubricate  the 
5. Wipe the inside  and outside  of the  distributor  cap 
6. Ensure that the carbon  brush works  freely in its 
7. Refit  rotor arm and distributor  cap 
cam 
bearing  and distributor  shaft. 
with  a soft  dry cloth. 
holder. 
Sliding contact type 
1. Remove  distributor  cap. 
2. Remove rotor arm. 
3. Lightly  smear the cam  with  clean  engine  oil. 
4. Add a few  drops  of thin  machine  oil to lubricate  the 
cam  bearing  and distributor  shaft. 
5. Wipe the inside  and outside of the distributor  cap 
with  a soft  dry cloth. 
6. Ensure  that the carbon  brush works  freely in its 
holder. 
7. Lubricate  the actuator  ramps and contact  breaker 
heel  ribs with  Shell  Retinax  or equivalent  grease. 
8. Grease the underside of the  heel  actuator. 
CLEAN  AND  LUBRICATE  DUCELLIER 
DISTRIBUTOR 
1. Remove  the distributor  cover and lift off the rotor 
arm  and anti-dust  shield. 
2. Inspect the contact  breaker  points; if burnt  or worn 
they should  be renewed. 
3. Very  lightly  smear the cam  with  grease - Shell 
Retinax. 
4. Lubricate  the pressure  pad with  grease - Shell 
Retinax. 
5. Add  a few  drops of oil to the  felt  pad  in the  top of 
the cam  spindle. 
6. Turn the engine  until the distributor  centrifugal 
weight  pivot post is visible  through  the cut
-out  in 
the  base  plate  and lubricate  the pivot  post with  a 
drop 
of oil.  Repeat  for the  opposite  pivot post. 
7. Carefully  wipe away  all surplus  lubricant;  and 
ensure  that the contact  breaker  points are clean 
and  dry. 
8. Fit the  anti-dust  shield. 
9. Refit  the rotor  arm, engage  the slot  in the  spindle 
and  push  down  firmly. 
10. Wipe  clean with dry nap-free  cloth, the inside  and 
outside 
of the  distributor  cover, particularly 
between  the electrodes,  and 
fit the distributor 
cover. 
9. Apply  grease  to the  fixed  pin and  actuator  fork. CLEAN V8 ENGINE  ELECTRONIC  IGNITION 
DISTRIBUTOR 10. Refit  rotor arm and distributor  cap. 
RR092 
80.000 km (48,000 miles) 
Remove the distributor  cap and  rotor  arm and wipe 
inside  with a nap-free  cloth. 
DO NOT DISTURB the clear  plastic  insulating  cover 
which  protects  the magnetic  pick-up module. 
19  
						

							MAINTENANCE 
CLEAN AND LUBRICATE  LUCAS DISTRIBUTOR 
1. Clean and  lightly grease  the cam with  Shell Retinax 
or  equivalent  and remove  any surplus  lubricant. 
2. Using the same  grease  lubricate  the underside  of 
the  heel actuator. 
3. Grease  the  actuator  ramps  and  contact  breaker 
heel  ribs. 
4. Apply grease  to the  fixed  pin and  the actuator fork. 
5. Apply  a drop of clean  engine  oil to the  felt  pad 
underneath the rotor  arm. 
6. Every 40.000 km (25,000 miles)  lubricate  the 
automatic  advance mechanism 
by injecting  one or 
two drops of engine oil through the  aperture in the 
base plate. 
7. Wipe  the internal  and  external surfaces of the 
distributor  cap with clean dry  nap
-free cloth and fit 
the  cap  to the  distributor  body. 
3 ST1084M 
3 
2 
ST 
CHECK AND ADJUST VS ENGINE  DISTRIBUTOR 
TIMING 
Using  Electronic  Timing Equipment 
A pointer  on the  timing  cover  and  marks  on the 
crankshaft pulley indicate  positions  around T.D.C. on 
No. 1 cylinder  (i.e. front cylinder  on left-hand  bank). 
Refer  to Engine  Tuning data  for appropriate  ignition 
timing. 
Engine  speed  accuracy during ignition  timing 
is 
important.  Any  variation from the required idle  speed, 
particularly  in an  upward  direction,  will lead  to wrongly 
set  ignition timing. 
1. Connect  a stroboscopic timing  light as instructed  by 
the  manufacturer.  The engine  is timed  on 
No. 1 
cylinder. 
2. Run the engine  at idle  speed. 
3. Position  the timing  light  to  illuminate  the 
crankshaft  pulley and scale. 
- 
WARNING:  Ensure that personnel  and equipment 
are  kept  clear 
of the rotating  cooling fan while  using 
the timing  light. 
t- 1. . 
4. If the  timing  is correct the  pulley mark indicated  in 
the Tuning  Data will show.  If correct,  instruction 
5 
may be ignored. 
5. With  the engine  still running  at idle  speed,  slacken 
the  clamp  bolt and carefully  rotate the  distributor 
body  as  required  until the correct  pulley  mark 
shows.  Turn anticlockwise  to advance  and 
clockwise  to retard. 
6. Tighten  the clamp  bolt with  the unit  in this 
position. 
g !, A, . .. 
20  
						

							MAINTENANCE I 10 I 
I, 1 *-‘r!t di. CLEAN, ADJUST OR RENEW SPARK PLUGS 
Refit or renew spark plugs .i;C’ I -2, . . 1.  Withdraw  the H.T. leads  from the  spark  plugs by 
2. Using  an appropriate  plug spanner,  remove  the 
gripping 
the shrouds,  do not  pull  on the leads. 
spark  plugs. 
ST1087M 
11. Check  that the washers  are fitted  to the  plugs. 
12. It is important  that  only  spark plugs  specified  in 
Data  section  are used for  replacements. 
13.  Incorrect  grades 
of plug may lead to piston  over- 
heating and  engine failure. 
14.  Wash  new plugs  in petrol  to remove  the protective 
coating,  then  set  the electrode  gaps to the 
appropriate  figures given in ‘Engine Tuning data’. 
15. Fit the  plugs  and washers  to the  engine  but do not 
overtighten. 
16.  Examine  high tension  leads, including  the coil  to 
distributor  lead,  for  insulation  cracking or 
corrosion  at end  contacts.  Fit new  leads  as 
necessary. 
17.  In addition  to correct  firing order,  high tension 
leads  must  be fitted  in  correct relation  to each 
other  to avoid  cross firing,  as illustrated.  This  is 
particularly  important on the  V8 engine. 
First  illustration.  4
-cylinder engine. 
Second illustration. 
V8 engine. 
shrouds  are firmly  seated  on plugs. Clean and  set gaps 18. When  pushing leads  on plugs  ensure  ferrules  within 
3. 
Fit plug in  plug cleaning  machine. 
4.  Wobble  plug  with  circular motion while operating 
abrasive  blast for 
a maximum  of four seconds. 
.. 
CAUTION:  Excessive abrasive  blasting  will erode 
insulator  nose. 
5. Change to air  blast  only and continue  to wobble 
plug  for a minimum  of thirty  seconds  to remove 
abrasive grit  from plug cavity. 
6.  Wire
-brush plug  threads, open gap slightly. 
7.  Using  point file,  square off electrode  surfaces. 
8. Set electrode  gap, see ‘Engine Tuning  data’, 
9. Test plugs  in accordance  with cleaning  machine 
manufacturer’s  instructions.  If satisfactory,  refit 
plugs in  engine. 
10. If no  machine  is available  carefully  wire  brush 
electrodes  and blow  or wash away  carbon particles. 
Illustration  shows: 
A. Dirty or unsatisfactory  electrode 
B. Filing plug electrodes 
C. A clean plug correctly  set 
ST052 
A B C 
ST051 
21  
						

							1x1 MAINTENANCE 
CLEAN AND TEST HEATER  PLUGS - Diesel  CHECK BRAKE  FLUID RESERVOIR 
engines 
REMOVE  THE PLUGS 
1. Check  the fluid  level in the  fluid  reservoir  by 
observing  the level  in relation  to  the 
‘MIN’ or 
‘MAX’ marks  on  the  side  of the  translucent 
reservoir. 
2. If  the  level  is below  the ‘MAX’ mark clean  the 
outside  of the  filler  cap and  top
-up with  new,  clean 
fluid  from  a  sealed container.  Use  only fluid 
recommended  in the  ‘General  specification  data’ 
section.  Refit the cap. 
1. Disconnect  the battery. 
2.  Remove  the terminal  nut from  each heater  plug. 
3. Detach  the heater  plug lead and washer  from each 
4. Remove the heater  plugs. Plug. 
Clean and inspect 
5. Remove  carbon from  base of heater  plugs to avoid 
the  possibility  of  short circuiting 
of the element. 
Do not sandblast. 
6. Examine  the element  for signs  of fracture  and 
deterioration and 
the seating  for scores.  Plugs  with 
fractures  or doubtful  elements  must be renewed. 
Where  scoring  of the  seating  may impair  the 
sealing, the  plug should  be renewed. 
Test  and refit 
7. Test  the plug  internal  circuit for continuity  by 
connecting 
it in  circuit with a  12 volt  side  lamp  bulb 
open  circuit  is indicated  and  the heater  plug  must 
be  renewed. 
and 
a 12  volt  supply.  If the  bulb  does  not light  an 
ST 1088M 
STlOPlM 
8. Ensure  that the  terminals  are clean  and  that  the 
thread  at the  base 
of the  plug  is free  from  carbon. 
9. Fit the  heater plugs to the engine. Do not 
overtigh  ten. 
10. Fit the heater  plug lead and washer  to each plug. 
11. Connect the battery. 
CHECK CLUTCH FLUID RESERVOIR 
1.  Clean and remove  the  reservoir cap and  observe 
the  fluid  level 
in relation  to the  marks on the side  of 
the reservoir. 
2. Top-up  if necessary  with new,  clean  fluid from a 
sealed  container  and of a recommended 
specification 
- see  ‘General  specification data’ 
section.  Refit  the cap. 
22  
						

							, ,I- z:. CHECK POWER STEERING FLUID RESERVOIR I..::..,.. 3 ..... .“d .*:. .. c’: ,..‘.,. ^... , .. 1. Clean  and  remove  the reservoir  cap and  observe 
the  fluid level 
in relation  to the  mark on the  side  of 
the  reservoir. 
2.  If necessary  top
-up with  a recommended  fluid - 
see ‘General specification data’ section - until the 
fluid  is 12 
mm (95 in)  above  the filter.  Refit the 
cap. 
CHECK COOLING SYSTEM COOLANT 
Refer  to  the  ‘Cooling system’  section  for  details of 
anti-freeze  and  inhibitors  and  to  the ‘General 
specification  data’ section  for  anti
-freeze  protection 
quantities. 
With  a cold  engine,  the  expansion tank  should  be 
approximately  half full. 
WARNING: Do not  remove  the  filler  cap when  the 
engine 
is hot  because  the  cooling  system is pressurised 
and  personal  scalding could result. 
To remove the filler  cap, first turn  it anti-clockwise 
a  quarter  of a turn and  allow all pressure  to escape, 
before  turning  further in the  same  direction  to lift  it 
off. 
When  replacing  the 
filler cap it is  important  that it 
is  tightened  down 
fuily, not just  to  the  first stop. 
Failure  to tighten  the filler  cap properly  may result 
in water loss, with  possible  damage to the  engine 
through overheating. 
// 
MAINTENANCE 
BATTERY 
Check Specific Gravity 
The  specific  gravity of the  electrolyte  should be 
checked  using a battery  hydrometer.  The readings 
should  be as follows: 
Temperate  climate  below 
26.5”C (80°F) as 
commissioned  for  service, fully charged  1.270 to 1.290 
specific  gravity. 
As  expected  during  normal service,  three
-quarter 
charged  1.230 to 
1.250 specific gravity. 
If  the  specific  gravity should  read  between  1.190 
to 
1.210, half-charged, the battery  must be bench  charged 
and  the electrical  equipment  in the  car  should be 
checked. 
Tropical  climate above 
26.5”C (80°F) as  commissioned 
for  service,  fully charged  1.210  to 1.230 specific gravity. 
As expected  during  normal  service,  three-quarter 
charge  1.170 to 1.190  specific  gravity. 
If  the  specific  gravity should read  between  1.130 to 
1.150, half-charged,  the battery  must be bench  charged 
and  the electrical  equipment 
on the car should  be 
checked. 
Check  and Top-Up Electrolyte  Level 
1. Wipe  all dirt  and  moisture from  the battery top. 
2.  Remove  the filler  cover.  If necessary  add sufficient 
distilled  water 
to raise the level  to the  top of 
separators. 
Replace the  filler plugs  or manifold lid. 
3. Avoid  the use  of a naked  light when examining  the 
ceils. 
4. In  hot climates it will be necessary  to top  up the 
battery  at more frequent intervals. 
5. In very  cold weather  it is  essential  that  the vehicle 
is  used immediately  after topping  up, to ensure  that 
the  distilled  water is thoroughly  mixed  with  the 
electrolyte.  Neglect of this  precaution  may result in 
the  distilled  water freezing  and causing  damage  to 
the battery. 
Battery terminals 
6. Remove  battery terminals, clean,  grease and refit. 
7. Replace  terminal  screw; do not  overtighten. Do 
not use  the screw  for pulling down  the terminal. 
8. Do NOT  disconnect  the battery  cables while the 
engine  is running  or damage  to  alternator 
semiconductor  devices may  occur.  It 
1s also 
inadvisable 
to break  or make  any connection in the 
alternator  charging and  control  circuits while 
the 
engine is running. 
9. It  is essential  to observe  the polarity  of connections 
to  the  battery,  alternator  and  regulator, as  any 
incorrect  connections  made  when  reconnecting 
cables  may  cause  irreparable damage to the 
semiconducto 
r devices. 
IMPORTANT  NOTE: If a  new  battery is fitted to the 
vehicle,  it should  be the same type  as fitted  to the vehicle 
when  new.  Alternative  batteries  may  vary  in size 
and 
terminal  positions  and  this  could  be a  possible  fire 
hazard  if the  terminals  or leads  come  into  contact  with 
the  battery  clamp assembly.  When fitting a new  battery 
ensure  that  the  terminals  and leads  are  clear  of the 
battery  clamp assembly. 
23  
						

							MAINTENANCE 
REMEW BRAKE SERVO FILTER 
1. 
2. 
3. 
4. 
5. 
6. 
7. 
Remove  the nuts securing  the  master  cylinder to 
the servo. 
Release  the clip  retaining  the  brake  pipe  to  the 
clutch  pipe. 
Separate  the master  cylinder from the servo. 
Disconnect  the vacuum  hose from the servo. 
Disconnect the Lucars  from the stop lamp  switch at 
the  rear  of the  pedal  box. 
Remove  the blanking  grommets  from  the pedal 
box.  Remove  the split pin  from the clevis  and withdraw 
the  clevis pin  and washer. 
8. Remove the  four  nuts  securing the servo  to the 
pedal  box and  remove  the servo. 
ST1533M 
i .- F 9. Pull  back  the dust cover. 
10. Release  the end-cap. 
11. Cut  the filters to remove  them from the shaft. 
%L. 
ST1485M 
12. 
13. 
14. Clean 
the filter  seating  and fit the  new  filters noting 
6.- 
* that they  must  be cut  to fit over the shaft. 
Fit the  end-cap  and  dust  cover  and refit  the servo 
and  master  cylinder 
to the vehicle  reversing  the 
removal  procedure.  Use  a  new split 
pin to secure 
the  clevis. 
Test  the brakes. 
24  
						

							MAINTENANCE I 10 I 
::... .. ! -j ENGINE SLOW RUNNING - 2.5 Diesel 
.;:y 1. Using a suitable  tachometer,  check the engine  slow 
running  adjustment 
see Engine  tuning  data. If 
adjustment is necessary  slacken the locknut  and 
turn  the  control  screw  clockwise to  increase  the 
revolutions  and anti
-clockwise to decrease  the 
engine  speed. Tighten  the  locknut,  increase  the 
engine  speed for 
a few  seconds  then re-check  the 
slow  running. 
.. ST1425M 
2. If a tachometer  is not  available  adjust the control 
screw until  the slowest  speed is obtained  consistent 
with  smooth and even  running. 
NOTE: The slow running  control is the only 
permitted  adjustment  in service. Any additional 
adjustments  required must 
only be carried out by 
authorised C.A.V. agents. 
25  
						

							Section 
12 
CONTENTS 
J 
2.25 LITRE PETROL  AND DIESEL ENGINE 
Page 
2 
12 
121 2.5 LITRE DIESEL  ENGINE 
2.25 LITRE PETROL AND DIESEL ENGINE CYLINDER  HEAD 
-Overhaul 53 
- Overhaul 94 
PETROL AND DIESEL ENGINES  FAULT DIAGNOSIS 12 
-Petrol engines 
-Diesel engines  123 
125 
1191 FUELSYSTEM-Petrol 
- Overhaul  mechanical  fuel  lift pump -Petrol & Diesel 
- Overhaul  electrical fuel lift pump 
- Overhaul  four cylinder  engine carburetter 
-Tune and adjust  four cylinder  engine carburetter 
- Overhaul V$ engine carburetter -Zenith 
-Tune and adjust V8 engine  carburetters - Zenith 
- Overhaul V8 engine carburetter - S.U. 
-Tune and adjust V8 engine  carburetter -S.U. 
-Fault tracing V8 engine  carburetters 
-Twin tank and in-tank fuel pump  installation 
1 
2 
3 
6 
7 
12 
15 
20 
24 
25 
1191 FUEL  SYSTEM - Diesel 
-Checking fuel injectors -Overhaul fuel injectors -Fitting fuel injectors 
-Turbo charger - supplement  34 
36 30 41 
- Engine 
protection 
- Drain and refill V8 engine cooling system 
-Drain and refill four cylinder  engine system 
- Radiator - remove  and refit 
- Fault Diagnosis 
1 
I 
L 
3 
7 
- Overhaul release  bearing assembly -Overhaul master  cylinder 1 
-Bleed Hydraulic system 3 
-Overhaul slave cylinder 3 -Clutch  pedal adjustment 4 
1 
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 
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 
To reduce repetition, operations  covered in this manual do not includc refcrence 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. 
1 engine and gearbox  assembly  removed, the water  pump end of the  engine  is referred  to as the  front. .-..-- .’’ ‘1 
.-- 
DIMENSIONS 
The  dimensions  quoted are to design cngineering 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 thc specification figurcs given in this 
Manual.  Thcsc  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 ANI) 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 thc 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. 
POISONOUS  SUBSTANCES 
Many liquids  and other  substances used in motor vchicles 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, 
iubricants and various  adhesives. 
. .,- . I. .. ... . ’ .. .: ... , , .. ,, 
FUEL HANDLING PRECAUTIONS yy+- 
The foliowing information  provides  basic precautions  which must be observed if petrol  (gasoline)  is to  be  handled 
safely. 
! also outlines  the other  areas of risk  which  must not  be  ignored. 
This 
intttrmation is  issued for basic  guidance  only, and in any case  of doubt  appropriate enquiries  should be made of 
your  local Fire Officer. 
II