Land Rover Defender Workshop 1993 Rover Manual

DEFENDER 
WORKSHOP MANUAL 
PART 
1 DATA AND MAINTENANCE 
SECTION  Introduction .................................................... 
SECTION  General  Specification  Data ................................ 
SECTION  Torque Wrench  Settings........................................ 
SECTION  Recommended   Lubricants, Fluids 
and  Capacities................................................... 
SECTION  Maintenance.......................................................  SECTION  Engine Tuning...

01 
PART ONE CONTENTS 
Section 
Number Page 
• Warnings  and cautions 1 
• References 1 
• Dimensions 1 
•  Repairs  and  replacements 1 
• Fuel handling precautions 1 
• Poisonous  and dangerous  substances  3 
• Accessories and conversions 4 
• Recommended  sealants 2 
• Disposing of used  oil and fluids  3 
• Specification  4 
• Special service tools  5 
• Abbreviations and symbols 6 
• Location  of vehicle  identification  and unit numbers  7 
• V8 engine  data  1 
• Propeller  shafts  3 
• Brakes  4...

07 
09 
10 
GENERAL  FITTING INSTRUCTIONS 
RECOMMENDED  LUBRICANTS, FLUIDS AND CAPACITIES 
PART ONE CONTENTS 
Page 
• Precautions  against damage 1 
• Safety precautions 1 
• Preparation 1 
• Dismantling 1 
• Inspection • general 2 
• Ball and roller  bearings 2 
• Oil seals 2 
• Metric bolt identification 4 
• Metric  nut identification 4 
• Hydraulic  fittings 4 
• Keys and keyways 5 
• Tab washers 5 
5 
6 
6 
6 
6 
• Joints  and joint  faces 3 
• Flexible  hydraulic  pipes, hoses 3 
• Recommended...

ENGINE 
EMISSION CONTROL 
PART TWO CONTENTS 
Section Number Page 
• Description 1 
• Engine fault diagnosis 7 
• Engine removal 11 
• Service  tools 49 
• Engine dismantle  and overhaul 13 
• Assembling engine 31 
• Emission control 1 
• Crankcase ventilation  system 1 
• Evaporative emission control 2 
• Fuel tank  evaporative control 
• Evaporative purge  system operation 
• Fuel tank  evaporative control system  operation 
• Fuel expansion tank - remove and refit 
• Heated  oxygen sensor - remove  and...

COOLING SYSTEM 
MANIFOLDS  AND EXHAUST 
CLUTCH 
PART TWO CONTENTS 
Section 
Number Page 
• Engine  protection 1 
• Drain and refill  cooling  system 
• Removing  water pump 2 
• Removing  thermostat 2 
• Removing  radiator 4 
• Cooling system fault diagnosis 
1 
5 
• Exhaust system  complete 1 
• Exhaust system  - remove  and refit 2 
• Exhaust  manifold  - remove  and refit 3 
• Clutch  assembly  renewal 1 
• Clutch fault diagnosis 2 
• Clutch release  bearing assembly - overhaul 3 
• Master cylinder -...

PART THREE CONTENTS 
Section 
Number Page 
1 - Remove  and refit 
- Overhaul  4 
- Data 41 
- Torque values  41 
- Service tools  42 
- Remove from LT77S gearbox 
- Overhaul 3 
- Torque wrench  setting 5 
- Dismantle 10 
1 
- Overhaul 1 
- Overhaul  Rear hub assembly 
- Overhaul rear axle  differential  assembly (Salisbury)  Defender 110 
- Overhaul rear axle  differential  assembly (Ninety) Defender 90 
1 
4 
12 
- Overhaul Front  hub assembly 
3 
- Stub axle shaft,  constant  velocity joint and swivel...

PART FOUR CONTENTS 
Section 
Number 
Page 
- Overhaul steering  column 1 
- Overhaul power steering  box 
- Power steering  system - Adwest lightweight  box 
- Test equipment  22 
- Adjust  power steering box - Adwest lightweight  box 
7 
21 
22 
- Pipe connections to steering box  23 
- Steering box sector  shaft seal  23 
- Power 
assisted steering  pump - overhaul 24 
- Power steering fault  diagnosis 29 
- Overhaul  drop arm bail joint 30 
- Track  rod and  draglink 32 
- Front  wheel  alignment 32...

Section 
Number Page 
- Chassis alignment and squareness 1 
- Chassis dimensions Defender 110 3 
- Chassis dimensions  Defender 90 5 
- Door lock mechanisms  Defender 110 6 
- Door trim Defender 110 7 
- Window regulators - rear side  doors  Defender 110 8 
9 
9 
10 
10 
11 
- Mounting panel - front doors  Defender  110 13 
- Door locking button - front doors  Defender  110 13 
- Window regulators - front doors Defender  110 14 
- Remote control lever - front doors Defender 110 14 
- Exterior  handle -...

PART FIVE CONTENTS 
Section Number Page 
- Remove. overhaul and refit 1 
- Introduction 1 
- Periodic Maintenance 2 
- Circuit diagram 5 
- Fault diagnosis 6 
- Charging and testing equipment 11 
- Depressurizing System                                                                                                                                12 
- Evacuating 13 
- Charging 15 
- Sweeping 14 
- Leak test 15 
- Pressure test 16 
- Compressor - remove  and refit 17 
- Drive belt  adjustment 17 
-...

Section 
Number Page 
- Chassis and radio  harness  connectors 38 
- Location of relays,  timers and control  units Defender 110 40 
- Location  of relays,  timers and control units  Defender 90 41 
- Fuses 42 
45 
- Multi-port fuel injection  circuit Defender 90 46 
47 
- Starting  system circuit Defender 110 48 
- Charging  and tachometer  circuit  Defender 110 50 
- Charging and tachometer  circuit  Defender 90 51 
- Hazard flasher circuit Defender 110 52 
- Hazard  flasher circuit Defender 90 53 
-...