Land Rover Defender Workshop 1993 Rover Manual

KEY TO MASTER CYLINDER 
1. Water  ingress  seal  10. 
Washer 
2. Transfer  housing 11. Recuperating  seal (primary cup) 
3. Vacuum  seal  12. 
Seal retainer 
4.  Guide  ring  13. 
Springs  (2 off) 
5. Retaining  ring  14. 
Swirl  tube 
6.  O 
ring seal  15. 
Master  cylinder  body 
7.  Primary  plunger assembly  16. 
Reservoir  seals 
8.  L seal  17. 
Reservoir 
9. Secondary  plunger  18. 
Low fluid  level  switch  and cap  

BRAKING SYSTEM 
Assembling master cylinder 21. Fit a new  retaining  ring on the  outer  surface 
of  the  master  cylinder  ensuring  that  the 
CAUTION: 
It is  important  that the following  serrations of the  ring  are facing  the  mounting 
instructions  are carried  out precisely,  otherwise 
flange. 
damage  could be caused 
to the new  seals  when 22. Fit the  two new  reservoir  seals  in their 
23.  Fit a new  vacuum  seal 
to either  the primary 
used  to lubricate  the parts  during...

BRAKING SYSTEM 
8. Remove the guide  ring from  the mouth  of the 12. Clean  all  parts with Girling  cleaning  fluid or 
master  cylinder  which  supports  the primary  unused  brake fluid  and  place the  cleaned 
plunger  assembly  and place  to one  side,  this  parts on 
to a clean  sheet of paper.  Inspect the 
component  is  not part 
of the  master  cylinder  cylinder  bore  and  plungers  for signs  of 
service  kit and 
is to be  refitted  on assembly of  corrosion,  ridges  and  score marks....

BRAKING SYSTEM 
RENEW BRAKE MASTER  CYLINDER  - Lucas  Fitting new master  cylinder 
Girling  type 
25,4 mm AS/AS 
Removing 
9. Insert  new reservoir  seals  in the  master 
cylinder  ports and fit  the reservoir by  reversing 
the  removal  method. 
1. Disconnect the battery. 10. Ensure  that  the  water ingress  seal  is in 
2. Place  a container  under  the master  cylinder  to  position  between master  cylinder  flange  and 
catch  escaping brake  fluid.  servo  and 
fit master cylinder  to servo...

BRAKING SYSTEM 
RENEW G VALVE - where  fitted 
The 
G valve  on  both right-hand and left-hand  drive 
vehicles  is  situated on the  right
-hand  side of the 
chassis,  within the engine  compartment,  attached 
to 1. Disconnect the brake  vacuum  hose from the 
a  bracket,  at the  commencement  of the  front  axle  servo non return  valve. 
arch. 
2. The  valve  is a  push fit in  the  servo  and to 
remove  it,  carefully prise  the  valve  out  with a 
Removing  screwdriver blade  between  the...

BRAKING SYSTEM 
RENEW BRAKE SERVO - L.S.C. 80 8. Remove  the two plugs  from each  side of the 
pedal  box. 
Removing 
9. Remove  the  split  pin,  washer and  clevis  pin 
securing  the servo  push  rod 
to the brake 
1. Disconnect  the battery.  pedal. 
2. Disconnect the electrical  leads  from reservoir 10. Remove  the  four  nuts (two each  side) 
cap.  retaining the  servo 
to the pedal  box and 
remove  the servo  and rubber  washer  from 
NOTE:  See operation  for renewing  the master  vehicle....

BRAKING SYSTEM 
FAULT CAUSE 
FADE Incorrect linings Badly lined shoes  Distorted 
shoes. Overloaded vehicle  Excessive 
braking  Old hydraulic  fluid 
Air  in system. Badly 
lined shoes. Shoes distorted  or incorrectly set.  Faulty drums. 
Weak  master cylinder mounting. 
SPONGY PEDAL 
A Disc Brakes 
REMEDY 
Replace the shoes, decrease vehicle  load or 
renew  hydraulic  fluid as necessary 
Check 
for air in the system  using a Hose 
Clamp  and  bleed if necessary  Check the 
master cylinder  mounting,...

CHASSIS AND BODY 
CHASSIS  ALIGNMENT AND SQUARENESS  3. Hold  a plumb  line against  each of the 
measuring  points in turn  and mark  the 
floor 
Frame alignment directly  beneath  the plumb-bob 
4  Move  the vehicle  and measure  diagonally 
With  the vehicle  assembled 
a check for chassis  between the marks  made on the  floor, if the 
squareness  can be made  as follows: 
chassis is square  the diagonals  between the 
related  measuring  points should  agree within 
1 Place the vehicle  on a level...

CHASSIS AND BODY 
DEFENDER 110 
2 REVISED: OCT 1993  

CHASSIS AND BODY 
DEFENDER 110 
CHASSIS  ALIGNMENT  DIMENSIONS 
A - Front Datum 
B - Chassis  Datum 
C - Front axle centre  line 
D 
- Rear  axle centre  line 
1.  4148 
- 4143  mm 
22. 594,2 - 593,4 mm 
2.  4009,5 
- 4005  mm 
23. 594,2 - 593,4 mm 
3.  978,7 
- 981,2  mm 
24. 283 - 282,2 mm 
4.  22 
- 20 mm 
25. 283 - 282,2 mm 
5.  252 
- 250  mm  26. 1970 - 1968  mm 
6.  239 
- 236,5  mm 
27 642,9 - 639,5 mm 
7  3023,3 
- 3022,3  mm  28. 590,5 mm 
8.  3030,7 
- 3028,7  mm 
29. 295,25 mm 
9.  155 
-...