Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

GENERAL FITTING REMINDERS
1
INFORMATION GENERAL FITTING REMINDERS
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a defnitive guide to automotive mechanics
or workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your...

07GENERAL FITTING REMINDERS
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INFORMATION PREPARATION
1.Clean components and surrounding area prior to
removal. Before removing a component, clean it
and its surrounding areas as thoroughly as
possible.
2.Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered...

GENERAL FITTING REMINDERS
3
INFORMATION BALL AND ROLLER BEARINGS
CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.
1.Remove all traces of lubricant from bearing
under inspection by washing in a suitable
degreaser; maintain absolute cleanliness
throughout operations.
2.Inspect visually for markings of any form on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any bearings found to be marked,...

07GENERAL FITTING REMINDERS
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INFORMATION OIL SEALS
NOTE: Ensure that the seal running track
is free from pits, scores, corrosion and
general damage prior to fitting
replacement seal.
1.Always fit new oil seals when rebuilding an
assembly.
2.Carefully examine seal before fitting to ensure
that it is clean and undamaged.
3.Coat the sealing lips with clean grease; pack
dust excluder seals with grease, and heavily
grease duplex seals in cavity between sealing
lips.
4.Ensure that seal spring, if provided, is...

GENERAL FITTING REMINDERS
5
INFORMATION JOINTS AND JOINT FACES
1.Always use correct gaskets where they are
specified.
2.Use jointing compound only when
recommended. Otherwise fit joints dry.
3.When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4.Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5.Inspect joint faces for scratches...

07GENERAL FITTING REMINDERS
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INFORMATION FUEL SYSTEM HOSES
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of
the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.
METRIC BOLT IDENTIFICATION
1.An ISO metric bolt or screw, made of steel and
larger than...

GENERAL FITTING REMINDERS
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INFORMATION COTTER PINS
1.Fit new cotter pins throughout when replacing
any unit.
2.Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3.All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1.When tightening a slotted or castellated nut
never loosen it to insert cotter pin or locking wire
except in those recommended cases where this
forms part of an...

07GENERAL FITTING REMINDERS
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INFORMATION UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity. 

LUBRICANTS, FLUIDS AND CAPACITIES
1
INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS
AMBIENT TEMPERATURE°C
COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50
Engine V8i Use oils to API 5W/20
service level
SG, SH 5W/30
or 5W/40
RES.22.OL.G4
or
ACEA A2:96 10W/30
10W/40
10W/50
15W/40
15W/50
20W/40
20W/50
Automatic gearbox ATF Dexron IID
Final drive units API or GL5 90 EP
Swivel pin
housings*MIL - L - 2105 or
MIL - L - 2105B, C
or D 80W EP
LT 230 API GL4 or GL5 90 EP
transfer gearbox MIL - L - 2105...

09LUBRICANTS, FLUIDS AND CAPACITIES
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INFORMATION Swivel pin housings
**Molytex EP 00 GREASE to specification XP153
Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake reservoir Brake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant Use an ethylene glycol based anti-freeze (containing no methanol)
V8i (aluminium) with non-phosphate corrosion...