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  assembly.  plunger or to the  bottom  of the  transfer 
housing  bore, open  face  of the  seal  towards 
the  primary  plunger guide  ring. 
is  essential.  24. 
Lubricate  the vacuum  seal  with  brake  fluid, fit 
the  transfer  housing 
to the master  cylinder, 
Also  thoroughly  check that no debris  of any  push the  housing  fully up 
to the cylinder 
description  is lodged  in any  of the  fluid  mounting  flange. 
DO NOT ADJUST THE 
passageways  and drillings. 
If debris  is found,  TRANSFER  HOUSING  AFTER FITTING. 
carefully  remove, clean the cylinder  and re
-check. 
25. Lubricate a  new water  ingress  seal  with brake 
fluid,  slightly  stretch  the seal  and  ease 
it down 
16. Fit  the  new swirl  tube to the bottom  of the  the  housing until the  seal is in the  correct 
cylinder  bore.  position between  the  housing  and flange. 
17. Lubricate the  secondary  plunger  and  cylinder 26. Roll  the reservoir  into the top of the  master 
bore.  Offer the plunger  assembly 
to the  cylinder,  reversing  the procedure  described  in 
cylinder  until  the  recuperation  seal is resting  instruction 3. 
centrally  in the  mouth  of the  bore.  Gently  27. Fit the  master  cylinder  to the  servo,  connect 
introduce  the  plunger  with a  circular  rocking  the  battery, and road  test the vehicle. 
motion,  as  illustrated.  Ensuring  that the  seal 
does  not  become  trapped,  ease the  seal  into 
the  bore  and slowly  push  the  plunger down 
the  bore  in one continuous  movement. 
inderting 
the plungers  into the cylinder  bore.  respective ports. 
Generous 
amounts of  new  brake  fluid should  be 
Never 
use old fluid or any  other  form of cleaning 
and  lubricating 
material. Cleanliness  throughout 
18. Fit the  primary  plunger  assembly using  the 
same  method  as 
for the secondary  plunger, 
push  the  plunger down  the bore. 
19. Fit  the  original  guide ring  to  support  the 
primary  plunger. 
20. Coat  a  new  O ring  with  brake  fluid and fit to 
its respective  groove on the  outer  location 
surface 
of the  master cylinder. 
NOTE:  The O ring  should  not be rolled  down 
the outer location  surface of the master  cylinder 
but  should  be slightly  stretched  and eased  down 
the  cylinder  and into 
its groove.  Do not  over 
stretch  the seal.  
						

							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.  Provided 
the  unit.  the  working  surfaces  are in perfect  condition, 
9. Pull the primary  plunger  assembly out of  the  new seals  from  a  Girling Service  repair  kit 
master  cylinder.  may be used. 
NOTE: The  primary  plunger  assembly  cannot be 
broken  down  any  further and  is  serviced  as  a 
complete  unit. Discard  the assembly.  Renewing secondary plunger seals 
secondary  plunger and discard: 
13. Remove the following  components  from  the 
NOTE: A small  screwdriver with  the end  rounded 
and  polished  is  required to remove  the 
L seal. 
DO 
NOT damage the  secondary plunger. 
A. Springs 
B.  Seal  retainer 
C. Recuperating seal (primary cup) 
D. Washer 
E. L seal 
10. The secondary  plunger  assembly will  remain 
at  the  bottom  of the  master  cylinder  bore,  the 
plunger  can  be easily expelled  by tapping  the 
assembly  on 
a piece of timber until the 
plunger  appears  at  the  cylinder mouth, 
carefully  pull the plunger 
out of the  master 
cylinder. 
11. If the  swirl  tube was not expelled  at the  same 
time  as the  secondary  plunger,  repeat  the 
above  operation 
to expel it from  the bottom  of 
the  master cylinder  bore and discard. 14. Coat  the new  seals  in unused  brake fluid and 
firstly fit  the L seal to the  plunger. 
15. Fit the  washer  followed  by the  recuperating 
seal.  Fit  the seal  retainer  and springs,  ensure 
the  springs are correctly  seated.  
						

							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  and 
3. Clean area  round master  cylinder  ports. 
secure  with the two  nuts  tightening  evenly to 
4. Disconnect  the  pipes from  master  cylinder  the correct  torque 11 to 17 Nm. 
ports.  Cover,  not plug,  the pipe  ends  to 
prevent entry 
of dirt. 
5. Disconnect  electrical leads from reservoir  cap. 
6. Remove  the two  nuts  securing  master  cylinder 
to servo  and withdraw  cylinder. 
7.  Remove  reservoir  cap and  drain  fluid into 
container  for disposal. 
WARNING: Do not  use  fluid  drained  or bled  from 
the  system.  Dispose 
of fluid as instructed  in 
SECTION 01 in a container  marked Used brake 
fluid
. 11. Connect  the brake  pipes  to the  master 
cylinder ports  and tighten 
to 16 Nm. 
12. Fill the  reservoir with  the  Correct grade of new 
fluid,  see 
SECTION 09, taken from a sealed 
container. 
13.  BIeed the brake system. 
14. Connect  the battery  and road  test vehicle. 
8. 
The  reservoir  is a  push 
fit in  the  master 
cylinder  and secured 
by seals.  Carefully  ease 
the  reservoir  from  the master  cylinder  by 
rolling 
it from  the seals,  as illustrated  in 
Master  Cylinder  Overhaul.  Note  that  the 
two 
seals are different  in size.  
						

							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  valve and 
grommet.  Take  care not 
to exert too much 
1. Disconnect the  battery.  pressure on the vacuum chamber. 
2. Disconnect from the G valve  the  pipe  union 3. Remove the rubber  grommet  but be careful 
from the  master  cylinder.  not to allow it to fall into 
the vacuum  chamber. 
3. Disconnect  from  the G valve the pipe  union 4. Check  the valve  for  correct operation; it 
to the rear  wheel  cylinders.  should  not 
be possible to pass  air through  into 
4. Remove  the nut and  bolt  securing the G  the  servo in direction  of arrow.  Do not  use 
valve 
to the  bracket.  compressed 
air. 
5. Release the valve  from the bracket. 
Fitting 
6. Fit the G valve to the  bracket  locating  the 
lugs  in the  holes which  are 
to ensure  that  the 
valve  is installed  at the  correct  angle.  RENEW 
SERVO NON RETURN  VALVE 
Remove 
NOTE:  The illustration  shows the latest  valve 
fitted  to the 
L.S.C. 80 servo  but the  principle of 
removal  and fitting  is the  same  for earlier  types. 
Fitting  new valve 
5. Fit the  rubber  grommet. 
6. Smear  the ribs of the valve  with  Lucas  Girling 
grease 
to assist  assembly,  and  push valve 
fully  home. 
7.  Connect  the vacuum  hose 
to the valve. 
8.  Road  test vehicle. 
7.  Secure  the valve  to the  bracket  with the  single 
bolt  and  nut. 
8.  Connect  the two pipes  to the  valve  and 
tighten  to 16  Nm. 
9.  Bleed  the brake  hydraulic  system and road 
test  the vehicle.  
						

							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. 
cylinder  for the  following  instructions  3 to  6. 
3. Disconnect  the vacuum  hose from servo. 
4. Clean  the  master  cylinder  round the area  of 
the  outlet  ports. 
5. Remove  the brake  pipes  from the master 
cylinder  and cover,  not  plug,  each pipe as 
it is 
released 
to prevent entry  of dirt. 
6. Remove  the two nuts securing  the master 
cylinder  to  the  servo  and carefully  remove  the 
master  cylinder.  Cover  the  ports 
to prevent 
fluid 
loss and  entry  of dirt. 
7.  From  inside the  vehicle,  release  the 
two brake 
pedal return  springs. 
Fitting servo 
11. Fit the  servo  and  rubber  washer to  the pedal 
box  and  secure  with  the four  nuts.  Tighten 
evenly 
to the  correct torque. 
12.  Connect the  brake  pedal to the  servo  with  the 
clevis  pin and  a new  split  pin. 
A washer  was 
fitted on earlier  installations. 
13. Fit plugs  to each  side of pedal  box. 
14. Attach the  pedal  return springs. 
15. Connect  the  vacuum  hose to the  servo  non 
return  valve.  Ensure  that the hose 
is in good 
condition. 
16. Fit  the  master  cylinder to the  servo  and 
secure  with  the 
two nuts. Tighten  to  the 
correct  torque. 
17. Fit the  fluid  pipes to the  master  cylinder  and 
tighten  to 
16 Nm. 
18. Top-up  the  reservoir  with new fluid  from  a 
sealed container  and bleed the  brake system. 
19. Connect the  electrical  leads  to the  reservoir 
cap. 
20. Connect  the  battery  and road  test the 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, lined  shoes and 
drums and  replace as necessary.  Renew the 
hydraulic  fluid 
if applicable. 
Check  the disc  run out does  not exceed 
A  
						

							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 floor. 9,50 mm 
2.  Mark  measuring  points at approximately  the 
5. Chassis frame dimensional  checks can be 
locations  shown in Fig. 
1 ensuring  that the  made, with the vehicle  upper structure 
marks  are exactly  opposite 
on each side of removed,  referring to the  applicable  illustration 
the  chassis  frame. 
and associated  key. 
REVISED: OCT 1993  
						

							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 
- 153mm 
30. 299,5 - 295,5  mm 
10.  871,2 
- 869,2  mm  31. 103 - 100 mm 
11.  2794  mm 
- wheelbase 
32. 1177,5 - - 1175,5  mm 
12.  488 
- 433 mm 
33. 1692,5 - 1689,5 mm 
13.  488 
- 433 mm 
34. 2610 - 2606 mm 
14.  82 
- 79,5 mm 
35. 2040,5 - 2037,5 mm 
15.  750,9  mm 
36. 1912,5 
- 1909,5 mm 
16.  750.9  mm 
37. 1359 
- 1357 mm 
17.  439,5 
- 436,5  mm 
38. 1573 - 1571 mm 
18.  439,5 
- 436,5  mm 
39. 270 - 268 mm 
19.  299,5 
- 295,5  mm 
40. 665,5 - 633,5 mm 
20.  500 
- 495 mm 
41. 440-438mm 
21.  500 
- 495 mm 
42. 32,25 - 31,25 mm 
REVISED: OCT 1993