Land Rover Defender Workshop 1993 Rover Manual

							INTRODUCTION 01 
INTRODUCTION 
This Workshop  Manual covers the Land Rover  Defender One  Ten  vehicles. It is primarily 
skilled  technicians  in the  efficient  repair and maintenance  of Land  Rover  vehicles. 
Individuals  who undertake  their own repairs  should have some  skill and training, and limit  repairs  to 
components  which could not affect  the safety  of the  vehicle  or its  passengers.  Any repairs  required  to 
safety  critical  items such as steering,  brakes, or suspension  should 
be carried out by a Land Rover 
Dealer.  Repairs  to such  items  should  NEVER 
be attempted  by untrained  individuals. 
WARNINGS 
and CAUTlONS are  given  throughout this  Manual  in the  following  form: 
WARNING:  Procedures  which must be followed  precisely  to avoid  the possibility of  personal injury. 
CAUTION:  This calls  attention  to procedures  which must be followed  to avoid  damage  to Components. 
NOTE:  This calls  attention  to methods  which make a 
job easier  to perform. 
REFERENCES 
References  to the  left- or right-hand  side in the manual  are  made  when viewing  the vehicle from the rear. With 
the  engine  and gearbox  assembly  removed,  the  water pump  end of the  engine  is referred to as the front. 
To  reduce  repetition,  operations  covered  in this  manual  do not  include  reference to  testing the vehicle after 
repair. 
It  is  essential  that work  is inspected  and tested  after completion  and if necessary a road  test of 
the  vehicle  is carried  out particularly  where safety related  items are concerned. 
DIMENSIONS 
The  dimensions  quoted  are to design  engineering  specification.  Alternative  unit  equivalents, shown in brackets 
following  the dimensions, have  been converted  from the original  specification. 
During  the period 
of running-in from  new,  certain adjustments  may vary  from  the  specification  figures  given in 
this  Manual.  These adjustments 
will be  re-set by the  Distributor  or Dealer  at the  After  Sales  Service,  and 
thereafter  should  be  maintained  at the  figures  specified 
in the Manual. 
REPAIRS  AND REPLACEMENTS 
When  replacement  parts are required  it is essential  that  only  Land Rover  parts are used. 
Attention  is particularly drawn  to the  following  points concerning repairs  and the fitting  of replacement parts  an 
accessories: 
Safety  features  embodied 
in the vehicle  may be impaired if other  than Land  Rover  parts are fitted. In  certain 
territories, legislation  prohibits the  fitting of parts  not 
to the  vehicle  manufacturer’s  specification.  Torque wrench 
setting  figures  given 
in the Repair  Operation  Manual must be strictly adhered  to. Locking  devices,  where 
specified,  must  be fitted. 
If the efficiency of a locking  device  is impaired  during  removal it must be renewed. 
Owners  purchasing  accessories while travelling  abroad should ensure  that  the accessory  and  its fitted  location 
on  the  vehicle  conform  to  mandatory  requirements existing 
in their country  of origin.  The  terms of the Owners 
Service  Statement  may be invalidated  by the fitting 
of other  than Land  Rover  parts. 
All  Land  Rover  parts have the full  backing  of the  Owners  Service  Statement. 
Land  Rover  Distributors  and Dealers  are obliged 
to supply  only  Land  Rover service  parts. 
FUEL HANDLING  PRECAUTIONS 
The following  information provides  basic precautions  which must  be  observed if fuel is to be  handled safely. It 
also  outlines the  other areas  of risk  which must not  be ignored. 
This  information  is issued  for basic  guidance  only, and in any  case  of doubt  appropriate  enquiries  should  be 
made 
of your  local  Fire Officer. 
Fuel  vapor  is highly  flammable  and 
in confined spaces is also  very  explosive  and toxic. 
When  fuel evaporates 
it produces 150 times  its own  volume in vapor,  which  when  diluted with air becomes a 
readily  ignitable mixture.  The vapor is heavier  than  air  and will always fall to the  lowest  level. It can readily  be 
distributed  throughout  a workshop  by air  current,  consequently,  even 
a small spillage of fuel is very  dangerous. 
designed 
to assist 
REISSUED: FEB 1993 1  
						

							01 INTRODUCTION 
Always  have a  fire extinguisher  containing  FOAM CO GAS, or POWDER close at hand when  handling  or 2 
draining fuel, or when  dismantling fuel  systems and in areas  where  fuel  containers  are stored. 
WARNING: It is  imperative  that the battery  is not  disconnected  during fuel system  repairs as arcing  at 
the  battery  terminal  could ignite  fuel vapor  in the  atmosphere.  Always disconnect  the vehicle battery 
BEFORE  carrying out work  on a fuel  system.  Whenever  fuel is being  handled,  transferred  or stored,  or 
when  fuel systems  are being  dismantled  all forms  of ignition  must be extinguished  or removed,  any 
lead
-lamps  used must be flameproof  and kept  clear 
NO ONE  SHOULD  BE PERMITTED  TO REPAIR  COMPONENTS  ASSOCIATED WITH FUEL  WITHOUT 
FIRST  HAVING  HAD SPECIALIST  TRAINING. 
HOT  FUEL  HANDLING  PRECAUTIONS 
Before commencing  any operation  requiring fuel drainage  from fuel tanks,  the following  procedures 
should 
be adhered  to: 
1. Allow sufficient  time for the  fuel  to cool,  thus avoiding  contact with hot fuels. 
2. Vent  system  by removing  the fuel  cap in a well  ventilated  area replace  cap until commencement 
of tank drainage. 
3. Before  disconnecting  any part  of the  fuel  system it is vital  to remove  dirt, dust  and debris  from 
around  components  to prevent  ingress of foreign  matter into the fuel  system.  Cover the tank 
apertures  after removal  to prevent  entry 
of dirt and  escape  of fuel  vapors. 
FUEL  TRANSFER 
WARNING:  FUEL MUST  NOT BE EXTRACTED  OR DRAINED  FROM ANY VEHICLE  WHILE IT IS 
STANDING  OVER A PIT. 
The  transfer  of  fuel from  the  vehicle  fuel  tank must  be carried  out in a  well  ventilated  area. An approved 
transfer  tank must 
be used  according  to  the  transfer  tank manufacturer’s  instructions  and local  regulations, 
including attention  to  grounding of tanks. 
FUEL  TANK  REMOVAL 
A fuel vapor  label should  be attached  to the  fuel  tank  upon  removal  from vehicle. ENSURE  TANK IS 
COMPLETELY  DRAINED. 
FUEL  TANK  REPAIR 
Under  no  circumstances  should a  repair  to any  tank be attempted. 
RECOMMENDED  SEALANTS 
A number of branded products are recommended in this  manual  for use  during  maintenance and  repair work. 
These  items  include: 
HYLOMAR GASKET AND JOlNTlNG  COMPOUND  and HYLOSIL  RTV SILICON 
COMPOUND. 
They  should be available  locally  from garage  equipment  suppliers. If there is any  problem 
obtaining supplies,  contact one 
of the following  companies for  advice and the address  of the  nearest stockist. 
Marston  Lubricants  Limited 
Hylo  House  Prudhoe 
Cale 
Lane, New Springs  Northumberland 
Wigan,  WN2 
1JR NE42 6NP 
Tel: 0942 824242  Tel: 0661 32014 
Fax: 0942 826653 
Fax: 
0661  35839 
Telex: 
67230 
Northern  Adhesives  Limited 
REISSUED:  FEB 
1993  
						

							INTRODUCTION 
POISONOUS  AND DANGEROUS  SUBSTANCES 
Many liquids  and  other  substances  used in motor  vehicles  are  poisonous  and should  under no circumstances 
be  consumed  and should  be kept  away  from open  wounds.  These  substances  among others  include 
anti
-freeze,  brake  fluid,  fuel, windscreen  washer additives,  air conditioning  refrigerant, lubricants and various 
adhesives. 
Engine  oils 
Prolonged  and repeated  contact  with mineral  oil will  result  in  the  removal  of natural  fats from  the skin,  leading 
to  dryness,  irritation and dermatitis.  In addition,  used engine  oil contains  potentially  harmful contaminates  which 
may  cause skin  cancer.  Adequate  means of skin  protection  and  washing  facilities should be provided. 
Health  protection  precautions 
1. Avoid  prolonged  and repeated contact with  oil particularly  used engine  oils. 
2.  Wear  protective clothing,  including impervious  gloves where practicable. 
3.  Do not  put  oily  rags  in pockets. 
4.  Avoid  contaminating  clothes, particularly  underpants, with oil. 
5.  Overalls  must be cleaned regularly.  Discard unwashable  clothing and oil impregnated footwear. 
t  aid  treatment should  be obtained  immediately  for open  cuts and wounds. 
barrier creams,  applying  before each  work period,  to help the  removal of oil  from  the  skin. 
h  with  soap  and water  to ensure  all oil is removed  (skin cleaners  and nail  brushes  will  help). 
Preparations  containing lanolin replace  the  natural  skin  oils  which have  been  removed. Do not  use 
petrol,  kerosene,  Diesel  fuel, gas oil, thinners  or solvents  for washing  skin. 
9.  If skin disorders develop,  obtain medical  advice immediately. 
10.  Where  possible, degrease components  before handling. 
11.  Where  there is a risk  of eye  contact,  eye protection  should  be  worn, for  example,  chemical goggles or 
face shields.  In addition,  an eye wash facility  should  be provided. 
Asbestos 
Some  components  on the  vehicle,  such as gaskets,  brake and clutch  linings  and friction  pads contain  asbestos. 
Inhaling  asbestos  dust is dangerous 
to health and  the following essential precautions  must  be observed. 
1. Work out  of  doors or in a well  ventilated  area and wear  a protective  mask. 
2. Dust found  on the vehicle  or produced during  work should  be  removed  by vacuuming  and not blowing. 
3. Asbestos  dust  waste should  be dampened,  placed in a sealed  container  and labelled  with what it 
contains to ensure  safe  disposal. 
4. If any machining,  cutting of drilling  is attempted  on materials  containing  asbestos the item  should  be 
dampened and  only  hand 
tools or low  speed power  tools used. 
Synthetic  rubber 
Many “O” ring  seals,  flexible  pipes  and other  similar  items which  appear  to be  natural  rubber,  are, in fact,  made 
of  synthetic  materials called  Fluoroelastomers.  Under normal operating conditions  this material  is  safe and does 
not  present  a health  hazard.  However,  if the  material  is damaged  by  fire or excessive  heating, it can  break 
down  and produce  highly  corrosive  Hydrofluoric  acid  which can cause  serious  bums on contact  with  skin. 
Should  the  material  be in a burnt  or over  heated  condition,  handle  only with  seamless  industrial gloves. 
Decontaminate  and dispose  of the  gloves  immediately  after  use.  If skin  contact  does  occur,  remove  any 
contaminated  clothing  immediately  and obtain medical  assistance  without  delay.  In the  meantime,  wash the 
affected  area  with  copious amounts  of cold  water  or limewater  for fifteen  to  sixty  minutes. 
DISPOSING  OF USED OILS AND  FLUIDS 
Environmental  protection precaution 
It is  illegal  to pour used  oil and  other  fluids  onto the  ground,  down sewers  or drains,  or into  waterways. 
Dispose  of used oil  through authorized  waste disposal contractors. 
REISSUED:  FEB 1993 3  
						

							01 INTRODUCTION 
ACCESSORIES AND CONVERSIONS 
Land  Rover  vehicles are designed  and constructed  for a variety  of uses  but no alterations  or conversions 
should  be carried  out to any  vehicle  produced  by Land  Rover  which could  affect  the safety  of the  vehicle  or its 
passengers. 
Land  Rover  has tested  and approved  a large  number  of accessories  and conversions,  suitable  for all  models. 
Before  fitting  any  accessory  or  commencing  any conversion  work to  any  Land Rover  vehicle,  check that  the 
accessory  or conversion  is approved by Land  Rover. 
WARNING: DO NOT FIT unapproved  accessories or conversions,  as they  could  affect  the safety  of the 
vehicle.  Land Rover 
will not accept  any liability for death,  personal  injury or damage to property  which 
may  occur 
as a direct  result of fitment  of non-approved  accessories or the carrying out of 
non
-approved  conversions  to Land  Rover  vehicles. 
SPECIFICATION 
Purchasers  are  advised  that the specification  details  set out  in the  Manual  apply  to a  range  of vehicles  and not 
to  any  one.  For the specification  of a particular  vehicle,  purchasers should  consult their  Distributor  or Dealer. 
The  Manufacturers  reserve the right  to vary  their  specification  with  or without  notice,  and  at such  times  and in 
such  manner  as they  think  fit. Major  as  well  as  minor  changes  may be involved  in accordance  with  the 
Manufacturer’s  policy of constant  product improvement. 
Whilst  every effort is made  to ensure  the accuracy  of the  particulars  contained in this  Manual,  neither the 
Manufacturer nor the  Distributor or Dealer,  by whom  this Manual is  supplied, shall in any  circumstances  be held 
liable  for any  inaccuracy  or the  consequences  thereof. 
COPYRIGHT 
© Rover Group Ltd 1993 
All  rights  reserved.  No part  of this  publication  may be  produced,  stored  in a  retrieval  system or transmitted  in 
any  form,  electronic,  mechanical,  photocopying,  recording or other  means  without  prior written  permission  of 
Rover Group  Ltd. 
‘4 REISSUED: FEB 1993  
						

							INTRODUCTION 01 
Special Service Tools 
The use of approved  special tools  is  important.  They are  essential  if service 
operations  are to be  carried  out efficiently,  and safely.  Where  special  tools are 
specified,  only these  tools should  be used  to avoid  the possibility  of 
personal  injury or damage  to the  components.  Also the amount  of time  they 
save  can be considerable. 
Every  special  tool  is designed  with the close  co
-operation  of Land  Rover  Ltd., 
and  no tool  is  put into  production  which has not been  tested  and  approved  by 
us.  New  tools  are  only  introduced  where an operation  cannot  be satisfactorily 
carried  out  using  existing  tools  or standard  equipment.  The user  is therefore 
assured  that  the tool  is necessary  and that it will  perform  accurately,  efficiently 
and  safely. 
Special  tools  bulletins  will be issued  periodically  giving  details of new  tools  as 
they are  introduced. 
All  orders  and enquiries  from the  United  Kingdom  should  be sent  direct  to V.  L. 
Churchill.  Overseas  orders  should be placed  with  the  local V. L. Churchill 
distributor,  where one exists.  Countries  where  there is no  distributor  may order 
direct  from V. L. Churchill  Limited, P.O. Box 3, Daventry,  Northamptonshire, 
England  NN11 4NF. 
The  tools  recommended  in this  Workshop  Manual  are listed  in a multi
-language,  illustrated  catalogue obtainable 
from  Messrs.  V. L.  Churchill  at the  above  address under publication  number VLC 2561/1/91  or from  Land  Rover 
Merchandising  Service, P.O. Box 534,  Erdington,  Birmingham,  B24 OQ5. 
REISSUED: FEB 1993 5  
						

							LOCATION  OF  VEHICLE  IDENTlFlCATlON  AND Key to Vehicle  Identification  Number Plate 
UNIT NUMBERS A Type approval 
VEHICLE  IDENTtFlCATlON  NUMBER (VIN) 
The  Vehicle  Identification  Number and the 
E Maximum  road weight - front axle 
recommended  maximum  vehicle weights  are 
F Maximum  road weight - rear axle 
stamped  on a plate  riveted 
to the  top  of the  brake 
pedal  box in the  engine compartment. 
The  number  is also  stamped  on the  right
-hand  side 
of  the  chassis  forward 
of the spring  mounting turret. 
Always  quote this number  when writing 
to Land 
Rover. 
B 
C 
D 
VIN  (minimum of 17 digits) 
Maximum  permitted laden  weight for vehicle 
Maximum  vehicle and trailer  weight 
The  Vehicle  Identification  Number identifies  the 
manufacturer,  model  range, wheel base, body type, 
engine,  steering,  transmission,  model  name  and 
place  of manufacture.  The following  example shows 
the  coding  process. 
SAL 
= Land Rover. 
LD 
H 
M 
V 
7 
A 
A 
= Land  Rover  Ninety  and One  Ten. 
= One  Ten inch. V = Ninety  inch. 
= 4 door station  wagon.  A = pick-up hood  cab 
truck  hard 
top. 
= V8. C = 2.5 Diesel.  D = 2.5 Petrol. 
B = 2.5 Turbo Diesel. 
= RH stg. with 5 speed  gearbox. 8 = LH stg. 
with 5 speed gearbox. 
= Ninety. B = One Ten.  E = Ninety, 
One  Ten 1988 model year. 
= Solihull build. F = Assembled locally 
from kit. 
The last six digits identify build  sequence 
number. 
The V8 engine  serial number is stamped  on a cast 
pad  on  the  cylinder  block  between  numbers 
3 and 5 
cylinders. 
REISSUED: FEB 1993 7  
						

							MAIN GEARBOX  LT77  FRONT AXLE 
Stamped  on a pad  on the  right-hand  side of the 
gearbox  immediately  below the oil filler level plug. 
Stamped  on  top of the left-hand  axle tube. 
TRANSFER  GEARBOX LT230T 
REAR AXLE 
Stamped on rear of left-hand axle tube  on 110, and 
on top of left-hand  axle tube  for 90 models (110 axle 
illustrated) 
. 
8 REISSUED: FEB 1993  
						

							GENERAL SPECIFICATION  DATA 
ENGINE 3.9 V8 
Type ........................................................................\
............. V8 
Number 
of cylinders ............................................................. Eight, two banks of four 
Bore 
........................................................................\
............. 94.00  mm 
Stroke 
........................................................................\
........... 71.12  mm 
Capacity 
........................................................................\
....... 3950  cc 
Valve  operation 
.................................................................... Overhead  by push-rod 
Compression  ratio 
................................................................ 9.35:1 
Maximum power 
................................................................... 134kW at 4750  rev/min 
Main journal  diameter 
.......................................................... 58.409-58.422 mm 
Minimum regrind  diameter 
................................................... 49.784-49.797 mm 
Crankshaft end thrust/(end float) 
......................................... Taken  on thrust washers of centre main bearing 
Crankshaft 
Minimum regrind diameter ................................................... 57.393-57.406  mm 
Crankpin journal  diameter 
.................................................... 50.800-50.812 mm 
0.10
-0.20  mm 
Main  bearings 
Number  and type ................................................................. 5, Vandervell shells 
Material 
........................................................................\
........ Lead-indium 
Diametrical clearance 
.......................................................... 0.010-0.048  mm 
Undersize  bearing 
shells ...................................................... 0.254 mm, 0.508 mm 
Connecting  rods 
Type ........................................................................\
............. Horizontally split big-end, plain small-end 
Length  between centres 
....................................................... 143.81-143.71 mm 
Big-end bearings 
Diametrical clearance .......................................................... 0.015-0.055  mm 
End
-float  crankpin ................................................................ 0.15-0.36mm 
Undersize  bearing shells 
...................................................... 0.254  mm, 0.508 mm 
Piston pins 
Length ........................................................................\
.......... 72.67-72.79 mm 
Diameter 
........................................................................\
...... 22.215-22.220  mm 
Fit
-in  connecting  rod ............................................................ Press fit 
Clearance in piston .......................................................         0.002-0.007 mm 
Type 
and material 
................................................................. Vandervell VP lead-indium 
REISSUED: FEB 1993 1  
						

							GENERAL SPECIFICATION  DATA 
Pistons 
Clearance in bore,  measured  at bottom 
of  skirt  at right  angles  to piston  pin 
...................................... 0.018-0.041 mm 
Piston  rings 
Number  of compression  rings .............................................. 2 
Number of control rings ........................................................ 1 
No 1 compression  ring ......................................................... 
No 2 compression  ring ......................................................... 
Width of compression  rings .................................................. 1.478-1.49 mm 
Oil  control  ring type 
.............................................................. Hepworth  and Grandage 
Oil control  ring width ............................................................ 3.0 mm 
Oil  control  ring rail gap 
......................................................... 0.38-1.40  mm 
Camshaft 
Location ........................................................................\
....... Central 
Bearings 
........................................................................\
....... Non  serviceable 
Number  of bearings 
............................................................. 5 
Drive ........................................................................\
............. Chain  9.52 mm pitch x 54 pitches. 
Molybdenum 
barrel faced 
Tapered and marked ‘T or ‘TOP 
Compression  ring gap 
.......................................................... 0.40-0.65  mm 
Tappets ........................................................................\
... Hydraulic-self-adjusting 
Valves 
Length: 
Seat  angle: 
Head  diameter: 
Stem  diameter: 
Stem 
to guide  clearance: 
Valve 
lift (Inlet and  Exhaust) ..............;................................. 9.49  mm 
Inlet 
................................... 116.59-117.35 
mm 
Exhaust 
............................. 116.59-117.35  mm 
Inlet 
................................... 45° to 45  1/2° 
Exhaust 
............................. 45° to  45  112° 
Inlet 
................................... 39.75-40.00  mm 
Exhaust 
............................. 34.226-34.480  mm 
Inlet 
................................... 8.664-8.679  mm 
Exhaust 
............................. 8.651-8.666  mm 
Inlet 
................................... 0.025-0.066  mm 
Exhaust 
............................. 0.038-0.078  mm 
Valve  spring  length  fitted 
...................................................... 40.4 mm at pressure of 29.5 kg 
Lubrication 
System  type....................................................................\
........  Wet sump,  pressure  fed 
Oil  pump type ........................................................................\
 Gear 
Oil  pressure 
........................................................................\
 2.11  to 2.81  kg/cm² (30 to 40 p.s.i) at 2400  rev/min 
with  engine  warm 
Oil  filter
-internal .................................................................... Wire  screen,  pump intake  filter in 
Oil filter-external ................................................................... Full  flow,  self-contained  cartridge 
2 REISSUED: FEB 1993