Land Rover Defender Workshop 1993 Rover Manual

							MAINTENANCE 
RENEW MAIN AND TRANSFER  GEARBOX OILS  DRAIN AND RENEW  LT230T TRANSFER 
DRAIN  AND REFILL  LT77S MAIN GEARBOX  GEARBOX 
OIL 
1. Drive the vehicle to level  ground  and place  a 1. Drive the vehicle to level  ground  and place  a  container under the gearbox to catch  the old 
suitable  container  under the gearbox 
to catch  oil. 
the  old  oil. 
2. Remove  the drain  plug and allow  the oil to 
2. Remove  the gearbox  and extension  case  drain. Fit the plug  using  a new  washer, if 
drain  plugs  and allow  the oil to drain  necessary, and tighten to the correct  torque. 
completely.  Wash the extension  case filter in 
3. Remove  the filler-level  plug and inject  the 
kerosene  and refit 
the plugs  using  new  approximate quantity of the recommended  oil 
washers,  if necessary,  and tighten 
to the  until it begins to run from  the plug  hole. Fit the 
correct  torque. 
level plug and tighten  only to the  correct 
torque,  do not  overtighten,  wipe away  any 
surplus  oil. 
3. Remove  the oil filler-level  plug and inject  the 
approximate  quantity of new  oil of the  correct 
make  and grade  until it begins  to run  out of 
the  filler
-level  hole.  Fit the plug  and tighten  to 
the  correct  torque.  Since the plug  has a 
Wipe  away  any surplus  oil. 
tapered 
thread it must  not 
be overtightened. 
10 REISSUED:  FEB 1993 
ST3084M ST1070M  
						

							MAINTENANCE 
RENEW SWIVEL  PIN HOUSING  OIL  RENEW FRONT AND REAR AXLE  OIL 
1. Drive the vehicle to level  ground  and place  a 1. Drive the vehicle  to level  ground  and place a 
container  under each swivel  housing  to catch  container under the axle to be drained. 
the  used  oil. 
2. Using  a spanner  with a 13 mm square  drive 
2. Remove  the drain  plug and allow  the oil to remove  the drain  plug and allow  the oil to 
drain  completely  and clean  and refit the plugs.  drain completely.  Clean and refit the drain 
recommended  make and grade 
of oil until  oil 3. Remove  the oil filler-level  plug and inject  new 
begins  to run  from  the level  hole.  Clean  and  oil of a recommended  make and grade  until 
it 
fit the level  plugs  and wipe  away  any surplus  begins to run from  the hole.  Clean  and fit the 
Oil. filler-level  plug and wipe  away  any surplus  oil. 
3. Remove  the oil filler-level  plug and inject  the  plug. 
LUBRICATE PROPELLER  SHAFTS 
1. Clean all the  grease  nipples on the  front  and 
rear  propshaft  universal joints, and sliding 
portion  of the  shaft. 
2.  Charge  a low  pressure  hand grease  gun with 
grease  of a recommended  make and grade 
and  apply  to the  grease  nipple. giving two to 
three  strokes  of the  gun  only  to each  nipple 
every  40.000  km (24,000  miles) intervals. 
RE-ISSUED: FEB 1993 11  
						

							MAINTENANCE 
GENERAL MAINTENANCE  AND ADJUSTMENT 4. Withdraw  the pad  retaining  pins. 
5. Remove  the anti-rattle  springs  and withdraw 
This second  part of the  maintenance  section covers  the friction  pads. 
adjustments  and items  of general  maintenance  as 
6. Clean the exposed  surfaces of the pistons 
dictated by the MAINTENANCE  SCHEDULES . with new hydraulic  fluid or brake  cleaning 
However,  only maintenance  operations that are not  fluid. 
included  in the  OVERHAUL  SECTlONS of the 
7. Using  piston  clamp (18G 672), press each 
manual  appear in this  section.  piston back into its bore,  whilst  ensuring  that 
the  displaced  fluid does  not overflow  from the 
EXAMINE  AND RENEW  DISC BRAKE  FRICTION reservoir. 
PADS 
NOTE: Defender  90 has  disc  type  brakes fitted to 
both  front  and rear 
axles. Defender 110 is fitted 
with  disc  type brakes  at the front and drum  type 
brakes 
at the  rear.  Front  brakes  on both  vehicle 
types  are 
fitted with four  piston  calipers  and the 
rear  brakes  on Defender 
90 are  fitted  with twin 
piston  calipers,  The procedure  for renewing 
friction  pads is the  same  for both  types  although 
there 
may be a  variation in the  type  of anti-rattle 
spring  fitted, see Section  70. 
Examine  the friction  pads for wear, 
if the  friction 
material  is less  than  3 mm  thick 
or oil contaminated, 
they  must  be renewed  as described 
in the  following 
instructions.  Observe precautions 
in SECTlON 01 
concerning  asbestos: 
CAUTION:  Friction pads must 
be changed in axle 
sets. 
1. Loosen  wheel nuts, jack-up the  vehicle,  lower 
onto  axle stands.  and remove  the 
wheels. 
2. Clean the exterior of me calipers. 3. Remove  the split  pins, or spring  clips, from 9. Insert the new friction pads. 
the pad  retaining  pins. 
8. Smear the faces  of the  pistons  with disc brake 
lubricant,  taking care not to allow  any to reach 
the  pad  lining  material. 
10.  Place  the anti
-rattle  springs  in position. 
11.  Insert  the pad  retaining  pins and secure  with 
new  split pins. 
12.  Apply  the foot  brake  pedal several  times to 
locate  the pads. 
13.  Check  the fluid  reservoir  and top up if 
necessary 
14  Fit the  road  wheels  and secure  with the nuts 
Jack  up the  vehicle  to remove  the axle  stands 
and  lower  me vehicle  to me  ground  Finally. 
tighten  the road  wheel  securing  nuts evenly. 
to  the  correct  torque. 
12 REVISED: OCT 1993  
						

							CHANGING THE HYDRAULIC  BRAKE FLUID 
In the  service  schedule  it IS recommended  that the  Pipes attached  to the  breathers  on the  axles 
brake  fluid is renewed  at 
18,000 miles (30.000 km) terminate  inside the engine  compartment. This allows 
intervals  or every  eighteen  months. If the following  the axles  to breath  whilst the vehicle IS traversing 
procedure  is adopted  air should  not enter  the  mud and water. 
No maintenance  is required  except 
system.  to ensure  that the pipes 
do not become  blocked, 
kinked,  or split,  or damaged  in any  other  way 
to 
prevent  proper breathing. 
AXLE BREATHERS 
1 Proceed  in the  same  way and order as for 
bleeding  the system,  see 
SECTION  70 . If a 
clear  plastic  bleed tube is not  available, 
CHECK  STEERING  BALL JOINTS 
interpose  a short  length of glass  tube into the 
bleed  hose being  used 
so that the passage  of 
the  fluid  can be seen. 
2. Attach  one end of the bleed  hose to the bleed 
nipple  of the  wheel  cylinder  nearest 
to the 
master  cylinder  and immerse  the 
free end into 
a  glass  vessel  containing  a small  quantity 
of 
brake  fluid so that the end of the  tube is 
below  the fluid  level. 
3. Unscrew  the bleed  nipple  screw about 
half
-a-turn,  enough to allow  fluid to be 
pumped  out. 
Air could be drawn  into the 
system 
if the  screw is withdrawn too far.  Ball 
joints  are lubricated  for their  normal  life during 
manufacture  and require  no further  lubrication.  This 
applies  only 
if the rubber  gaiter has not become 
dislodged  or damaged.  The joints  should  be checked 
at  the  specified  mileage intervals  but more  frequently 
if the vehicle  is used under arduous  conditions. 
MAINTENANCE 
1. Check for wear in the joints  by moving  the 
ball  joint 
up and  down  vigorously. If free 
movement is apparent  renew the complete 
joint  assembly. 
4 Pump-out most,  but not  all,  of the  fluid  from 
the  reservoir  by continuously  depressing and 
releasing  the foot  pedal.  Do not,  however, 
allow  the reservoir  to empty  completely. 
5.  Top-up  the reservoir  with new,  unused  fluid. of 
the  correct  specification,  from a sealed 
container.  See SECTION  09 . 
6.  Ensure  that the reservoir  is kept  topped
-up 
and  continue  bleeding  until the old and 
discoloured  fluid is dispelled  and the new  fluid 
is  seen  passing  through the clear  bleed  hose 
or  glass  tube. Continue  to bleed  for two  full 
strokes  of the  pedal  and then  close  the bleed 
nipple  whilst the pedal  is depressed. 
7  Repeat  the above  procedure  at the  remaining 
wheel  cylinders  in turn. 
8.  Top
-up the  reservoir  and road  test the vehicle. 
RE-ISSUED:  FEB 1993 ‘7  
						

							MAINTENANCE 
CHECK FRONT WHEEL  ALIGNMENT  ADJUST 
REAR BRAKES  DEFENDER  110 ONLY 
Recognised  front wheel  alignment  tracking 1. Raise up vehicle  and lower  onto axle stands. 
equipment  should be used 
to perform  this check. 
See 
SECTION  04 for wheel  alignment  data. Before 
checking  the alignment  make the following  checks:. 
2. Each shoe is independently  set by means of a 
hexagon  adjuster.  Check that the wheel  turns 
freely  and turn  one adjuster  until the shoe 
IS 
locked  against  the drum.  Slacken  off the 
adjuster  sufficiently 
for the wheel  to turn  freely 
approximately 
two serrations on the  snail 
3. Repeat  the  above  procedure for the second 
brake  shoe and the opposite  wheel. 
4. Remove  the axle  stands  and road  test the 
vehicle  brakes. 
a. The vehicle  is on  level  ground. 
b. The vehicle is not loaded. c. The  tire pressures  are correct.  cam. 
d. The wheels  run true  and are not damaged  or 
buckled. 
e. The  track  rod is not  damaged or bent  and the 
ball  joints  are not worn. 
Also check  that the 
joints  are assembled 
in the same  angular 
plain  and are central 
in their  housings.  See 
SECTION 57. 
1. Set the road  wheels  to  the  straight  ahead 
position and move the vehicle forward a short 
distance  at least 
two revolutions  of  the 
wheels. 
2. Set  up the  tracking  equipment  to  the 
manufacturers  instructions. 
3. Position the trammel  probes on the  inner  face 
of the wheel,  not the  rims, if the latter  are 
damaged. 
4. Check  the alignment  as instructed by the 
equipment  manufacturers  and repeat  the 
check  on 
the opposite  wheel. If adjustment is 
required  follow the instructions in steering 
SECTION 57. 
14 REVISED: OCT 1993  
						

							ADJUST TRANSMISSION  BRAKE  (Handbrake) 6. Fit the  clevis  pin, washer  and  a NEW split pin. 
7. Slacken  the  adjuster 1 or 2 notches  until 
1. Set the vehicle  on  level  ground  and chock the  handbrake shoes just  clear the drum. 
wheels. 
8. Apply  the handbrake  gradually. The  drum 
2. Release the  handbrake  fully.  should 
still  rotate on  the  first ratchet and start 
3. Remove  the clevis  pin connecting  the to come on at the  second  ratchet. 
handbrake  lever 
to the  relay  at  the  gearbox 
end. CAUTION:  DO NOT  over  adjust  the handbrake, 
the  drum  must be free  to rotate  when the 
handbrake  is released,  otherwise  serious damage 
will  result. 
DRAIN FLYWHEEL  HOUSING 
1. The flywheel  housing can  be  completely 
sealed 
to exclude  mud and water  under 
severe  wading  conditions,  by means  of a  plug 
fitted  in the  bottom  of the  housing. 
2. The  plug  should only be fitted  when  the 
vehicle  is expected 
to do  wading or very 
muddy  work. 
3. When the  plug  is in  use it must  be  removed 
periodically  and  any oil  allowed 
to drain off 
before  the plug  is replaced. 
4. When the  plug is not  in use,  it must  be stored 
as  shown. 
4. Turn  the adjuster  on  the back plate clockwise 
until  the shoes  are  fully  expanded against  the 
drum. 
5. Adjust  the outer  sheath  of the  handbrake 
cable  by  means 
of the two locknuts at the 
gearbox  end  until  the  holes  in the  clevis  on 
the  inner  cable line up 
with the hole in the 
relay  lever 
REISSUED: FEB 1993 15 
MAINTENANCE 
ST3078M  
						

							MAINTENANCE 
ST3413M 
FILTERS FUEL FILTER 
AIR CLEANER  ELEMENT 
Removing WARNING: Ensure that the fuel  handling 
precautions  given 
in Section 01 - Introduction 
1. Release the three  clips and remove  the inlet  regarding  fuel handling  are strictly  adhered  to 
tube.  when carrying 
out the following  instructions. 
2. Remove the nut and end  plate. 
3. Withdraw  element and discard. WARNING: The  spilling  of fuel is unavoidable 
during  this operation.  Ensure that all necessary 
Refitting  precautions are taken  to prevent  fire and 
explosion. 
Removing  Remove 
and refit 
4. Insert  the new  element  and reassemble  the 
unit  in reverse  order 
to removal. 
1. Depressurise  the fuel  system. 
2. The  fuel filter  is located  on the  right-hand 
chassis  side member  forward of the  fuel  tank 
filler  neck.  Access 
to the filter  is gained 
through  the right
-hand  rear wheel  arch. 
3. Clamp  the inlet  and outlet  hoses to prevent  of 
fuel  spillage  when disconnecting  the hoses. 
4. Loosen  the two fuel unions  and remove  the 
hoses 
from the  filter  canister. 
5. Release  the single  nut and  bolt securing  the 
filter  and clamp  and remove  the filter. 
AIR  CLEANER DUMP VALVE 
The dump valve  provides  an automatic  drain for the 
air  cleaner  and 
is fitted in the  base  of the  air cleaner 
support  bracket. 
Checking 
1. Squeeze  open the dump  valve and check  that 
the  rubber 
is flexible  and in good  condition. 
2. If necessary  remove the dump  valve to clean 
the  interior. 
3. Fit a new  valve if the original is in a poor 
condition. 
Refitting 
6. Fit a new  filter  observing  the direction  of flow 
arrow  on the  canister. 
7. Tighten  the single  nut and  bolt. 
8.  Fit the  inlet  and outlet  hoses.  Tighten  the 
unions  to a torque  of (27
-34Nm). 
9. Refit  the fuel  pump  relay.  Reconnect  the 
battery  and recode  the radio. 
10. Start  the engine  and inspect  for fuel  leaks 
around  the hose  connections. 
16 REISSUED: FEB 1993  
						

							MAINTENANCE 
Charcoal canister Defender 110 3. Disconnect  pipe. 
Remove 
4. Loosen  bolt and  remove  charcoal  canister 
1. Disconnect  battery negative  lead. 
2. Disconnect  both purge  lines. 
3.  Release  canister from its mounting  bracket. 
Refitting 
5. Reverse the removal  procedure. 
POSITIVE  CRANKCASE  VENTlLATION  INTAKE 
FILTER 
1. Pry the  filter  holder  upwards  to release it from 
the  rocker  cover. 
2. Discard  the sponge  filter. 
Refit 
4. Reverse  the removal  procedure,  ensuring that 
the  canister 
is securely  located in its mounting 
bracket  and both  purge  lines are fitted 
correctly  to the  canister. 
WARNING: The use of compressed  air to clean  a 
charcoal  canister  or 
to clear  a blockage in the 
evaporative  system  is highly  dangerous.  An 
explosive 
gas present in a  fully  saturated 
canister  may 
be ignited by the  heat  generated 
when  compressed  air passes 
through the 
canister. 
Charcoal canister  Defender 
90 
Remove  Fit 
new  filter 
3. Insert a new filter  into the plastic  body 
4. Push the filter  holder  onto the rocker cover 
until it clips firmly  into place 
1. Disconnect  battery negative  lead. 
2.  Pry out  purge  valve. 
REVISED:  OCT 1993 17 
3  
						

							CLEAN PLENUM  CHAMBER  VENTILATION 7. Any remaining  consolidated  matter can be 
PASSAGEWAY dislodged  using a piece of soft bent wire or a 
pipe  cleaner.  Finally the passageway  must 
The  cleaning 
of the plenum  chamber  ventilation  again be blown  out to remove  any remaining 
passageway  can be carried  out without  removing  the  debris. 
plenum  chamber  from  the ram  housing. 
8. Remove  the small T piece  between  the 
crankcase  ventilation  hoses and check  that 
it 
CAUTION: Care must be taken  to prevent  debris  is free  from  blockages,  clean as necessary 
from  the passageway  passing beyond the throttle 
9. Refit  the ‘T’ piece  and hoses,  tighten  the hose 
valve  disc.  clamps securely. 
WARNING: Safety glasses  must be worn when CLEAN  POSITIVE  CRANKCASE  VENTILATION 
performing this operation.  Ensure that debris is 
not blown  into the atmosphere  which could be 
harmful  to other  personnel  within the vicinity. 1. Release  the hose  clamp  and pull the hose off 
the canister. 
1. Disconnect  the battery  negative  terminal. 2. Unscrew  the canister  and remove if from  the 
2. Release  the hose  clamp  and remove  the hose  rocker 
cover. 
from  the plenum  chamber  inlet neck. 
3. Remove  the large O ring  from  the threaded 
3. Remove  the crankcase  ventilation hose 
from  end of the canister. 
the  side 
of the  plenum  chamber. 4. Visually inspect the condition of the wire 
4. Insert  a piece  of lint  free  cloth  down  the  screen within the canister, if in poor  condition 
throttle  valve bore to prevent  debris passing  fit 
a new  assembly, 
if in an  acceptable 
beyond  the throttle  valve. 
5. Place a cloth  over the tube  protruding  from 
the  side 
of the plenum  from which  the 
ventilation  hose was removed  to prevent 
debris  from the passageway  being blown  into 
the  atmosphere. 
BREATHER  FILTER 
condition clean the screen  as follows: 
5. Immerse  the canister in a small  amount of 
solvent  and allow time tor the  solvent 10 
dissolve  and loosen any engine  fume debris 
within the canister. 
6. Remove  canister from solvent  bath and allow 
to  dry  out  in still  air. 
WARNING: Do  not  use  a compressed  air line  to 
remove  any remaining  solvent or particles  of 
debris  within the canister  as this  could  cause  fire 
or  personal  injury. 
Refitting  the breather/filter 
6. Use  a compressed  air line with a slim  bent 
nozzle 
to enable  the passageway  to be 
cleaned out from within the  throttle  valve bore. 
7 
8. Screw  the canister  into the rocker cover hand 
9. Refit  hose  and tighten  hose clamp  securely 
Fit 
a new  rubber 
0 ring. 
tight  only. 
I 
18 RE-ISSUED:  FEB 1993 
MAINTENANCE  
						

							RR2171E 
MAINTENANCE 
RR1876E 
GENERAL  MAINTENANCE AND ADJUSTMENTS 
CHECK/ADJUST  OPERATION 
OF ALL WASHERS 9. Ensure  that replacement H.T. leads  are 
AND TOP-UP  RESERVOIR refitted  in their  spacing  cleats in accordance 
with  the correct  layout illustrated. 
Failure 
to observe  this instruction  may result 
in  cross-firing  between two closely  fitted leads 
which  are consecutive  in the  firing  order. 
Fitting H.T. leads 
1. Check  the operation of windscreen,  tailgate 
and  headlamp  washers. 
2. Adjust jets if necessary  by inserting  a needle 
or very  fine sharp  implement  into the jet orifice 
and  maneuvering 
to alter  the jet direction. 
3. Unclip  the reservoir  cap. 
4. Top up reservoir  to within 25mm (1 in) below 
the  bottom 
of the filler  neck. 
Use  a screen  washer  soIvent/anti-freeze  in the 
reservoir,  this 
will assist in removing  mud, 
flies  and road  film and  protect  against 
freezing. 
IGNITION 
Spark  plugs 
1. Take great  care when  fitting  spark plugs not 
to  cross
-thread  the plug,  otherwise  costly 
damage 
to the  cylinder  head will result. 
2.  Check  or replace  the spark  plugs as 
applicable. 
3. It  is  important  that only  the correct type of 
spark  plugs are used for replacements. 
4. Incorrect  grades of plugs may lead to piston 
overheating  and engine  failure. 
To remove  spark plugs  proceed  as follows: 
5. Disconnect  the battery  negative  lead and 
remove  the leads 
from the spark  plugs. 
6.  Remove  the plugs 
and washers. 
7. Set the  electrode  gap to the  recommended 
clearance. 
8. When  pushing  the leads  onto the plugs, 
ensure  that the shrouds  are firmly  seated 
on 
the plugs. 
RE-ISSUED: FEB 1993 19