Land Rover Defender Workshop 1993 Rover Manual
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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 Data............................................. SECTION General Fitting Instructions................................ 2. ENGINE AND ENGINE SYSTEMS SECTION Engine ............................................................. SECTION Fuel System ..................................................... SECTION Cooling System.............................................. SECTION Manifold and Exhaust ........................................ SECTION Clutch............................................................... 3. TRANSMISSION SECTION Manual Gearbox............................................... SECTION Propeller Shafts ............................................... Front and Rear axle differentials ...................... Front Axle and Final Drive................................... SECTION Transfer Gearbox SECTION SECTION 4. CHASSIS AND BODY SECTION Steering .......................................................... SECTION Suspension .................................................... SECTION Chassis and Body ........................................... SECTION Brakes ........................................................... 5. AIR CONDITIONING AND ELECTRICAL EQUIPMENT SECTION Heating and Ventilation ...................................... SECTION Air Conditioning .................................................. SECTION Electrical Equipment .......................................... Published by Land Rover, Lode Lane, Solihull, West Midlands, B92 8NW. England. ©Land Rover 1993 Publication Part Number: LDAWMEN93US
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 • Transmission 3 • Suspension 3 • Steering 4 • Electrical equipment 5 • Replacement bulbs and units 6 • Vehicle dimensions 7 • Vehicle weights and payload 7 • Wheels and tires 8 • Tire Pressures 8 04 06 INTRODUCTlON GENERAL SPECIFICATlON DATA ENGINE TUNING DATA TORQUE WRENCH SETTINGS • V8 engine tuning data 1 • Engine 1 • Fuel lines 1 • Gearbox 2 • Transfer box 3 • Rear axle and final drive 4 • Clutch 1 • Front axle 3 • Propeller shafts 4 • Rear suspension 4 • Steering and front suspension 4 • Power assisted steering 5 • Brakes 5 • Electrical 5 • Air Conditioning 5 REISSUED: FEB 1993
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 lubricants 1 • Anti-freeze 2 • Capacities 3 • Workshop maintenance schedules 1 • Lubrication 9 • General maintenance and adjustment 12 REISSUED: FEB 1993 MAINTENANCE
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 refit Charcoal canister - remove and refit • Charcoal canister - purge valve - remove and refit 2 2 3 4 4 5 5 • Positive crankcase ventilation • Air intake filter - remove and refit 6 • Breather filter - remove and refit 6 • • Emission label 7 - Diagnostic equipment 1 • Hot wire multiport fuel injection 2 • Engine tuning 4 • Multi meter checks 4 • Multi port fuel injection • circuit diagram 5 • Base idle speed setting 6 • Fuel pressure check 7 • Injector tests 7 • Removing air cleaner 8 • Removing mass air flow sensor • Removing throttle position sensor • Removing idle air control valve • Removing vehicle speed sensor • Removing fuel injection • relay modules • Removing inertia fuel shut-off switch • Removing engine fuel temperature sensor • Removing engine coolant temperature sensor • Depressurising fuel system 12 • Removing fuel pressure regulator • Removing ram housing 19 • Removing intake manifold 19 • Removing fuel filter 20 • Removing fuel tank and fuel pump 8 9 9 10 10 11 11 11 12 • Removing fuel rail - injectors r/h and l/h 13 • Removing plenum chamber 14 21 • Removing accelerator cable 23 • Removing accelerator pedal 24 FUEL SYSTEM
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 - overhaul 3 • Slave cylinder • overhaul 5 • Clutch pedal adjustment 6 • Bleed clutch hydraulic system 6 • Renew clutch slave cylinder 7 • Renew clutch master cylinder 8
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 assembly - Front axle differential 8 - Dismantle 11 1 - Inspection 14 - Data 23
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 - Overhaul rear suspension 1 - Levelling unit - Functional check - Coil spring specification 2 - Remove levelling unit 3 - Panhard rod 6 - Radius arm 6 - Front shock absorber 7 - Front road spring 8 - Bump stop 8 - Anti-roll bar front 9 - Anti-roll bar ball joint links front 10 2 - Description 1 - Overhaul front brake calipers 2 - Overhaul rear brakes 5 - Overhaul transmission brake 6 - Bleeding the brakes 8 - Renewing front brake discs 9 - Overhaul master cylinder - Lucas Girling 2.4 mm AS/AS 15 - Renew master cylinder - Lucas Girling 2.4 mm AS/AS 11 - Renew G valve 16 - Renew servo non-return valve 16 - Renew brake servo 17 - fault diagnosis 18 RE-ISSUED: FEB 1993
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 - rear side door Defender 110 15 - Door latch assembly - rear side door Defender 110 16 - Glass - front doors Defender 110 17 - Locking barrel - front doors Defender 110 18 - Rear window side trim Defender 110 19 - B post trim Defender 110 21 - Rear quarter light trim Defender 110 22 - Grab handles Defender 110 22 - Door lock, rear door Defender 110, front and rear doors Defender 90 23 - Exterior handle - rear side door Defender 110 - Door locking button - rear side door Defender 110 - Remote control lever - rear side door Defender 110 - Door latch assembly - rear side door Defender 110 - Door glass - rear side door Defender 110 REVISED: OCT 1993
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 - Condenser fan motors - remove and refit 17 - Condenser and receiver/drier - remove and refit 18 - Evaporator 19 - Resistor block 22 - Electrical precautions 1 - Distributor - Lucas 35DLM8 remove and refit 2 - Distributor - Lucas 35DLM 8 overhaul 5 - Ignition timing adjustment 5 - Electronic ignition - preliminary checks 6 - Alternator - type A1 27 remove and refit 9 - Battery 9 - Starter motor - Lucas M78R 10 - Headlamps 12 - Side, tail and flasher lamps 15 - Rear number plate lamp 15 - Rear lamps 16 - Reverse light switch 16 - Warning lamps 17 - Instrument illumination 17 - Wiper motor overhaul 18 20 21 22 - Electrical systems 23 - Air conditioning fans harness 24 - Chassis harness 25 - Main harness 26 - MFI harness 28 - Radio harness 29 - Engine harness connectors 30 - Air conditioning fans harness connectors 33 - Multi-port fuel injection harness connectors 34 - Main harness connectors 36 - Renew wiper motor and drive rack - Renew windscreen wiper arms - Renew windscreen wiper wheel boxes - Engine harness 24 REVISED: OCT 1993
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 - Dimming mirror circuit Defender 110 54 - Reverse and stop lamp circuit Defender 90 and 110 55 - Heated front screen circuit Defender 110 56 - Rear window demist circuit Defender 110 57 - Horn, clock, interior light and auxiliary circuits Defender 110 58 - Horn, clock, interior light and auxiliary circuits Defender 90 - Radio system circuit Defender 110 60 - Radio system circuit Defender 90 61 - Lighting circuit Defender 110 62 - Lighting circuit Defender 90 63 - Front wash/wipe system circuit Defender 90 and 110 64 - Rear wash/wipe system circuit Defender 110 65 - Warning lights/check circuit Defender 90 and 110 66 - Audible warning system circuit Defender 110 67 - Audible warning system circuit Defender 90 68 - Coolant temperature gauge circuit Defender 110 69 - Coolant temperature gauge circuit Defender 90 70 - Fuel tank level indicator circuit Defender 90 and 110 71 - Battery condition indicator circuit Defender 110 72 - Auxiliary feed circuit Defender 90 72 - Centre differential locked circuit 73 - Cigar lighter circuit Defender 90 and 110 73 - Split charge and voltage sensitive switch circuit Defender 110 74 - Trailer circuit Defender 110 75 - Multi-port fuel injection circuit Defender 110 - Air conditioning circuit Defender 110 - Starting system circuit Defender 90 48 59 REVISED: OCT 1993