Land Rover Defender Workshop 1993 Rover Manual

							COOLING SYSTEM 
COOLING SYSTEM DRAIN AND FILL COOLING SYSTEM 
Engine  Protection  WARNING: Do not  remove the  radiator 
filler cap 
To  prevent  corrosion  of the  aluminium  engine parts 
it when the engine  is hot  because  the cooling 
is vital  that  the  cooling system is filled with a solution  system is pressurized  and  personal  scalding 
of  clean  water  and  anti
-freeze winter  and  summer.  could result. 
Never 
fill or  top-up  with  water only, always  add 
anti
-freeze.  Never use  salt  water otherwise corrosion 
will occur.  In  certain  territories  where  the only 
available  water supply  may have  some  salt  content, 
use  only  clean  rainwater  or distilled  water,  with 
anti
-freeze  added. 
Use 
only Universal anti-freeze  or permanent  type 
ethylene base,  without methanol  containing, 
a 
suitable  inhibitor  for aluminium  engine parts. Use one 
part  of anti
-freeze to one  part  water.  Anti-freeze 
should  be  used even in climates  where  is  it  not 
necessary  as  a corrosion  inhibitor. 
No other 
corrosion  inhibitor  should  be  used. 
A concentration 
of  at  least  50% should  be maintained. 
Anti
-freeze  can remain  in the  cooling  system  and will 
provide adequate  protection  for two years  provided 
that  the specific  gravity of the  coolant  is checked 
before  the onset 
of the second  winter  and  topped-up 
with  new  anti
-freeze as required. 
The  specific  gravity  can be checked  with a 
hydrometer  and a 50%  concentration  at 
68° F (20° 
C  shouId read 1.075. 2. Disconnect  bottom hose and drain  cooling 
Land Rovers  leaving the factory  have  the  cooling  system. Connect  hose after  draining. 
system filled  with a 
50% anti-freeze  mixture.  This 3. To  drain  the expansion  tank remove  it from 
gives  protection  against frost down  to minus 
47° C  the vehicle,  empty.  flush-out  and  refit. If 
(minus  53° F). 
necessary renew the expansion  tank hose. 
After  the second  winter  the  system  should be 
4. Make up a solution of anti-freeze  and  water  in 
drained  and thoroughly  flushed.  Before  adding  new a separate  container  in the  concentration 
anti
-freeze  examine  all joints  and renew  defective  required. The cooling  system  capacity  is 
hoses 
to make  sure that  the  system is leak  proof. 
quoted in the  data  section.  Therefore to allow 
See  SECTION 
09 for protection quantities. 
for  topping up and the expansion  tank make 
up  a quantity 
in excess of this  quantity. 
5. Although  anti-freeze may not be required  it 
should 
be used  as an  inhibitor  see under 
Engine  Protection. 
6. Fill the  system  through  the  radiator  filler  plug 
until  the coolant  is just 
below the  filler  neck. 
7. Fit the plug  but do not  over  tighten. 
8. Half fill the  expansion  tank with  coolant  and 
secure  the cap  correctly. 
1. Remove the  radiator  filler  plug.  
						

							COOLING SYSTEM 
To Refit 
9. Clean the timing  cover mating  face and 
ensure  all trace 
of old  gasket  is removed. 
10.  Smear  a small  quantity  of grease  on both 
sides  of  a new gasket  and place 
it in position 
on  the timing  cover. 
11. Clean  the threads  of the  four  long  bolts  that 
penetrate the  cylinder block  and  apply  Loctite 
572 
to the  threads. 
12. Fit  the  water  pump to the engine  and secure 
with  the  retaining 
bolts and  single  stud that 
also  secures 
the alternator  adjustment  strap. 
13. Fit the  bottom  hose to the water  pump  and 
radiator. 
14. Fit  the  fan  cowl, if removed. 
15. Fit and  tension the  drive belt. 
9. Start and run  the  engine until normal 16. Fit the fan  and viscous  coupling. 
operating  temperature  is reached.  Allow the 
engine 
to cool and  check  the levels  in the 
radiator  and  expansion  tank and  top  up 
if 
necessary.  Finally  check all hose  connections 
for  leaks. 
REMOVING WATER PUMP 
NOTE: The  following  instructions  cover the basic 
vehicle  without  air conditioning  and power 
steering.  It may  therefore 
be necessary to 
remove  other items  in order  to gain  access  to the 
water  pump. 
To  Remove 
1. Disconnect the  battery. 
2.  Disconnect  the  bottom  hose  from  the radiator 
to drain  the cooling  system. 
3. Using a  cranked open-ended  spanner,  remove  17. Fill the cooling  system with the required 
the  fan and  viscous  coupling  assembly,  noting  concentration  of recommended  anti
-freeze in 
that  it has a  left
-handed  thread.  accordance  with  the  instructions  in  this 
section. 
4. 
If necessary,  remove  the fan cowl. 5. Remove the fan drive  belt. 18. Connect  the battery  and  run the engine  while 
6. Remove the bottom  hose from the  water  checking for leaks. 
7. Release  the alternator  adjustment  strap  from REMOVING THERMOSTAT 
8. Remove the fourteen  bolts  and  withdraw the To Remove 
ST3166M 
pump. 
the  water  pump stud. 
water  pump  and gasket. 
1. Disconnect  the battery  and drain  the  cooling 
NOTE: Information  relating to the  inspection of system. 
the  water  pump  is contained  in the  engine 2. Remove  any pipes,  hoses,  or other  items  that 
overhaul  section 12. may inhibit  access to the  thermostat  housing. 
3. Remove  the thermostat  cover  and  withdraw 
the  thermostat.  Clean any deposits 
from the 
housing  and the cover.  
						

							COOLING SYSTEM 
4. The temperature  at which  the thermostat 7. Fit the  thermostat  cover using a new  gasket. 
should  be  fully  open is  stamped  on  the  Coat the threads 
of the  retaining  screws  with 
forward  end  of the  thermostat.  The following  Loctite 
572 and tighten  the  screws  evenly to 
method can  be  used to determine if the  the correct  torque. 
thermostat 
is satisfactory  and suitable  for  8. Connect  all pipes  and hoses  and refill  the 
refitting.  cooling system in accordance  with  the 
instructions  in this  section. 
5. Place  the thermostat  and  a Centigrade 
thermometer 
in a  laboratory  beaker, or a 
suitable  alternative,  half 
full of water.  Heat the 
water  and  observe  the  temperature at which 
the  thermostat  opens. 
If faulty,  discard  the 
thermostat. 
To Refit 
6. The  thermostat  has a small vent hole in which 
is  fitted  a jiggle  pin 
to keep the hole  clear. Fit 
the thermostat  to  the  housing  ensuring that 
this  vent  is uppermost  at the 
12 oclock 
position. 
If fitted in any  other  way,  an  air  lock 
could  result  in the  water  passages  causing 
overheating  and coolant 
loss from  the system.  
						

							COOLING SYSTEM 
REMOVING RADIATOR  To Refit 
To  remove 
12.  Lower  the radiator  into position  in  the  engine 
compartment,  ensuring  that  the 
two pegs  at 
1. Disconnect the  battery.  the  bottom  of the  radiator  locate in the 
2. Drain the cooling  system.  corresponding rubber pads in  the  cross 
3. Disconnect  the expansion  and overflow  hoses  member brackets. 
from  the top of the  radiator. 
13. Locate  the  cowling  into  the  clips at the  bottom 
4. Release  radiator support  bracket  fixings and of the radiator  and secure  it to the top  with 
detach  brackets.  the four  screws. 
5. Slacken  top  hose clip, detach  hose and place 14. Secure  the  top  of the  radiator  with the two 
aside.  brackets  and  bolts. 
6. Place a suitable  container  under  the oil cooler 15. Secure the  top and  bottom  hoses. 
hose  connections. 
16. Connect  the oil cooler hoses to the radiator. 
7. Disconnect oil cooler  hoses at cooler  and 17. Connect  the  expansion  tank and overflow 
place  aside.  hoses. Ensure  all hose  clips  are  fully 
8.  Slacken  bottom  hose  clip, detach  hose and  tightened. 
place aside.  18. Refill  cooling  system with  correct  coolant 
9. Remove  the  screws  securing  the  cowling  to mixture. 
the radiator. 
10. Lift  the  cowling  out of the clips  at the  bottom 
of the  radiator  and push  it  back towards  the 
engine. 
11. Carefully lift the  radiator  out of the  engine 
compartment.  19. 
Check  and 
top up engine oil  as necessary.  
						

							COOLING SYSTEM FAULT DIAGNOSIS 
SYMPTOM  POSSIBLE 
CAUSE CURE 
A-EXTERNAL LEAKAGE 1.Loose hose  clips  1.Tighten 
2Defective  rubber hose  2.Renew 
3. Damaged  radiator seams  3. Rectify 
4. Excessive  wear in the  water  pump 4. Renew 
5. Loose core plugs  5. Renew 
6. Damaged  gaskets  6. Renew 
7. Leaks  at the  heater connections  7. Rectify 
or plugs 
8. Leak 
at the water  temperature  8. Tighten 
gauge  plug 
1.  Defective  cylinder head gasket 
2. Cracked  cylinder wall 
3. Loose  cylinder head bolts 
1. Boiling 
2. Internal  or external  leakage 
3. Restricted radiator  or inoperative 
B-INTERNAL  LEAKAGE 1. Renew.  Check engine oil for contamination 
and  refill  as necessary 
2. Renew  cylinder block 
3. Tighten.  Check engine  for 
oil contamination 
and  refill  as necessary 
1. Ascertain the cause of engine overheating 
and  correct  as necessary 
2. See  items A and  B 
3. Flush radiator  or renew  the thermostat  as 
necessary 
1. See item  D 
2. Refill 
3. Use air  pressure from engine side  of the 
radiator and thoroughly clean  matrix 
C-WATER LOSS 
F-OVERHEATING 1. Poor  circulation 
2. Dirty  oil and sludge  in engine 
3. Radiator fins choked  with chaff, 
mud,  etc 
4. lncorrect ignition  timing  4. Check using electronic  equipment 
5. Insufficient  coolant  5. See item D 
6. Low 
oil level  6. Replenish 
7. Tight  engine 
7. New engines  are very  tight and moderate 
speeds  should be maintained  for the first 
1,000 miles 
8. Choked  or damaged exhaust  pipe 8. Rectify  or renew  silencer 
or  silencer 
9. Dragging brakes  9. Adjust brakes  10. Overloading  vehicle 
10. ln the hands of the operator 
11. Driving in heavy  sand or mud 
12. Engine  labouring 
on gradients 
13. Low  gear work 
14. Excessive  engine idling 
16. Defective thermostat  16. Renew 11. In 
the hands  of the  operator 
12. In  the hands  of the operator 
13.ln  the hands  of the  operator 
14. In  the hands  of the  operator 
15. lnaccurate  temperature gauge  15. Renew 
I 
D-POOR CIRCULATION 1. Restriction in system 1. Check hoses  for crimps,  reverse-flush  the 
2. lnsufficient  coolant 
2. Replenish 
I 
3. lnoperative water  pump  3. Renew 
4. Loose  fan belt 
4. Adjust 
5.  Inoperative  thermostat  5.Renew 
radiator, 
and clear  the system 
of rust  and 
sludge  
						

							SYMPTOM POSSIBLE CAUSE CURE 
E-CORROSION 1. Excessive impurity in the  water 1. Use only soft, clean  water  together with 
correct anti-freeze  or inhibitor  mixture 
2. 
lnfrequent flushing  and draining of 2. The cooling  system should be drained and 
system  flushed thoroughly 
at least  once  a year 
3. 
lncorrect anti-freeze  mixtures  3. Certain anti-freeze solutions have  a 
corrosive  effect 
on parts of the cooling 
system. Only  recommended  solutions should 
be used. 
G-OVERCOOLING 1. Defective  thermostat  1. Renew 
2.  Inaccurate  temperature  gauge 2.Renew  
						

							MANIFOLDS AND EXHAUST 
EXHAUST SYSTEM COMPLETE 
ST3420M 
NOTE: Ensure no exhaust  leaks  are evident  in 
either  a new  or old  exhaust  system, as  this 
will 
affect vehicle  performance.  disconnect  any components  until exhaust  system 
WARNING: To prevent  personal  injury  occurring 
from 
a hot  exhaust  system, DO NOT attempt  to 
has cooled  down.  
						

							MANIFOLDS AND EXHAUST 
EXHAUST SYSTEM  EXHAUST MANIFOLD 
Remove  and refit 
Removing  Left hand 
Remove 
and refit 
1. Raise  the vehicle  on  a suitable  hoist  and Right hand 
apply the parking  brake. 
2. Disconnect  the electrical  plugs from  the Removing 
heated  oxygen  sensors. 
3. Remove  the three  nuts securing  each  front 
pipe 
to the  manifold.  and  remove the  gaskets. 
4. Remove the two nuts and bolts  securing  the 
front  pipe 
to the intermediate  pipe. 
5. Withdraw the front  pipes  with catalysts. 3. Remove  the manifold(s)  and old gaskets. 
6. Remove  the two nuts and bolts  securing  the 
intermediate  pipe to the tail  pipe. 
7. Remove  the nut and bolt securing the  tail  pipe 
mounting  bracket.  Withdraw the tail pipe  and 
silencer,  and collect  the rubber  mounting. 
8. Remove  the nut  and  bolt  securing 
intermediate  pipe front  and rear  mountings. 
Withdraw  the  intermediate pipe and silencer 
and  collect  the  rubber  mountings. 
1. Disconnect  the  front  exhaust pipe(s) from  the 
2. Tap back  the bolt  locking tabs  and  remove  the 
eight  bolts,  lock tabs  and  washers. 
Refitting 
NOTE:  Apply Firegum  Putty, part no. 
15608 to all 
exhaust  system joints with the exception  of the 
exhaust  flange to manifold  flange, where a new 
gasket  should  be fitted. 
9. Reverse  the removal  instructions. 
Refitting 
4. Ensure  that the mating  surfaces of the 
cylinder  head and exhaust  manifold are  clean 
and  smooth. 
5. Coat  the threads  of each  bolt  with anti-seize 
compound. 
6. Place  the manifold  and  new gaskets  in 
position  on  the cylinder  head  and 
fit the 
securing  bolts,  new lockplates  and plain 
washers.  The  plain  washers  are 
fitted between 
the  manifold  and lockplates. 
7. Evenly  tighten the  manifold  bolts to the  correct 
torque,  see  torque  wrench  settings  section 
06, 
and bend  over the lockplate  tabs. 
8. Reconnect the front  exhaust  pipe, using  new 
exhaust  flange gaskets. 
INTAKE  MANIFOLD 
The removal  and  refit of the intake  manifold is 
incorporated in the Fuel  Injection  System,  Section 
19. 
manifold(s).  
						

							ASSEMBLY  RENEWAL  SPECIAL TOOLS CLUTCH 
The major  part of clutch  assembly  renewal is the LRT-12-001 Clutch  centralising  tool 
removal  of the  transmission 
to gain  access  to the 
clutch.  Because  of the  considerable combined  weight 
Remove 
of the main  gearbox  and transfer  box and  the off-set 
centre 
of gravity, it is  vital  that clutch  replacement 1. Remove  the transmission,  see SECTION 37. 
must only  be  undertaken  by organisations  or 2. Mark the position  of the  clutch  cover to the 
individuals  that  have the necessary  experience  and  flywheel to assist 
with reassembly. 
essential  equipment 
to enable  the  transmission  to  be 3. Working evenly  and  diagonally  remove  the 
removed  safely, without  the risk 
of personal  injury  clutch  cover  securing bolts. 
and  damage 
to the transmission  and vehicle.  Details 4. Do not disturb  the three  bolts  in the  clutch 
of the recommended  transmission  hoist  and special  cover. 
cradles  are contained  in 
SECTION 37. 5. Remove clutch cover  assembly. 
6. Withdraw  the  clutch  friction plate. 
Always  ascertain  the reason 
for the necessity  to 
renew  the clutch  before  attempting to 
fit a new 
assembly.  Careful  examination 
of the  clutch  and the 
associated  components  should be carried  out. This 
should 
also include  checking  the clutch  hydraulic 
system 
if the reason  for clutch  failure  is not 
immediately apparent.  See 
Clutch Fault Diagnosis. 
If oil is present  on the  clutch  lining the  source of the 
oil  contamination  should  be investigated. 
If 
necessary,  the rear  main  bearing  oil seal  should  be 
renewed  as described 
in SECTION 12 . 
Excessive  wear of the  clutch  due  to the vehicle 
having  been used continually  for wading  without  the 
flywheel  housing  plug  being fitted,  would  be  evident 
by 
rust on  all  parts  including  the release  assembly 
and splines 
of the  primary  shaft. 
The  clutch  cover  and friction  plate should  always  be 
7. Reverse items 5 and 6, aligning the assembly 
renewed  together.  Also it would  certainly  be wise to replace  the release  bearing  and possibly  the  marks and  using  the centralising tool I 
8. Fit the  cover  securing  bolts,  working  in  a 
When  fitting the clutch 
it is important  that the splines  diagonal  sequence. Finally tightening  the  bolts 
to a torque of 28Nm. of the  primary  shaft are smeared  with Molybdenum 
Disulphide  grease such as Rocol 
M.T.S. 1000 to 9. Refit the transmission. 
prevent  seizure. 
Also the friction  plate must  be 
centralised while the  cover bolts are  evenly tightened 
to  the  correct  torque.  Refitting 
remainder 
of the  mechanism if any  wear is present.  LRT-12-001.  
						

							CLUTCH DRAGS - Start with check  No. 20 and  proceed  as directed. 
POSSIBLE CAUSES  CHECK AND ACTION 
1 Free play at  the clutch  pedal  Yes Check3 No Check2 
2  Clutch  pedal tight on the  pivot  shaft  Yes Free the clutch pedal  and lubricate 
No Check 3. 
3  Clutch  release  mechanism  sticking  Yes Free the mechanism 
No Check4 
4 Clutch  slave or master  cylinder pistons seized or sticking  Yes Repair or renew the cylinder No Check 5. 
5 Clutch  diaphragm cracked  Yes Renew the cover  plate No Check6 
6. Friction plate  worn  Yes Renew  the friction plate No Check7 
No 
No Check 9 
No Check  10 
No Check 11 
piston seals leaking No Check 12 
No Check 13. 
No Check  14. 
No 
No Check 16. 
piston seals leaking No Check 17 
No Check 18. 
No Check  19 
No Check20 
No Check21 
No Check22 
Yes 
No Check 23. 
No 
7 Oil on  the friction  plate linings  Yes  Renew the friction plate and rectify the oil leak 
Suspect the  friction plate sticking  on splines 
8. Engine or gearbox  rnountings  worn or slack  Yes Tighten or renew the mountings 
9 Drive shaft joints/propeller  shaft joints  or splines  worn  Yes Renew components as  necessary 
10. Clutch release  mechanism  sticking or detective  Yes Free or renew the  release mechanism. 
11. Clutch slave or master  cylinder pistons sticking  or  Yes  Repair or renew  the cylinder 
12  Friction  plate cushion  springs broken 
or weak  Yes  Renew the clutch assembly complete. 
13.  Riven  plate sticking on  splines  Yes Free 
the driven plate. 
14  Friction plate  distorted 
or oil on the linings Yes Renew the friction plate and rectify the oil leak i- 
15. Clutch release  mechanism or  dutch pedal sticking  Yes Free as necessary. 
16.  Clutch  slave or master  cylinder  piston sticking 
or Yes  Repair or renew the  cylinder. 
17. Friction plate  sticking on splines  Yes Free the friction plate. 
18 Friction plate  distorted  Yes Renew the  friction plate. 
19.  Clutch  diaphragm detective  Yes Renew  the cover  plate 
20 Internal  or external clutch  fluid leaks  Yes Repair or renew as  necessary 
21  Friction  plate sticking  on splines  Yes Free the friction  plate 
22.  Oil on 
the friction plate 
23  Friction  plate distorted  Yes Renew the friction plate 
Suspect a 
faulty cover  plate or damaged 
flywheel 
Renew  the friction plate and rectify  the oil leak 
Suspect a  faulty  cover  plate