Land Rover Defender Workshop Rover Manual
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REARSUSPENSION 5 REPAIR ANTI-ROLL BARLINKS Service repairno-64.35.24. Remove 1. Remove 2nuts, bolts, washers andrubber bushes fromlinks andlower anti-roll bartoclear links. 2. Remove cotterpinand loosen castellated nuta few turns. 3. Release linkusing special tool18G 1063A as shown. 4. Remove castellated nutand remove link. Refit 5. Fitanti-roll barlink arm andcastellated nut.Point link arm down asshown. Tighten fixingto 40Nm (30 lbf/ft) and fitnew cotter pin. 6. Align anti-roll bartolinks. 7. Fitbolts, washers andrubber bushes usingnew self locking nutsandsecure anti-roll bartolinks. Tighten to 68Nm(50lbf/ft). SELF LEVELLING UNIT Service repairno-64.30.09 Remove WARNING: Thelevelling unitcontains pressurised gasand MUST NOTbe dismantled. Repairisby replacement of complete unitonly. 1. Raise andsupport thevehicle underchassis and use ajack tosupport weightofthe axle. 2. Disconnect upperlinksatpivot bracket. 3. Ease uplevelling unitlower gaiter andunscrew lower balljoint atpush rodusing thinjawed spanners. 4. Release webbing strapfromthechassis. 5. Remove 4nuts securing topbracket tochassis and withdraw levellingunitcomplete with bracket. Renew levelling unitballjoints The balljoints forthe levelling unitmay bedismantled for cleaning andexamination. 6. Unscrew lowerballjoint from pivot bracket. 7. Unscrew balljoint from topbracket. 8. Reassemble balljoints, packing with Dextagrease G.P.orequivalent. Renewjointsif worn. 9. Check condition ofgaiters andrenew if necessary.
64REAR SUSPENSION 6 REPAIR Refit 10. Ensure ballpinthreads areclean andsmear Loctite gradeCVXonball pinthreads. 11. Fitupper balljoint tolevelling unitand secure gaiter. 12. Fittop bracket complete withlevelling unitto chassis andsecure with4nuts andtighten to 47 Nm (35lbf/ft). 13. Fitlevelling unittolower balljoint andsecure gaiter. 14. Attach webbing straptochassis crossmember. 15. Fitupper linkstothe pivot bracket andretain with 2bolts andnuts butdonot tighten atthis stage. 16. Remove jackinsupport ofaxle andsupport from under chassis. 17. Allow suspension tosettle andthen tighten 2 bolts andnuts retaining upperlinkstopivot bracket to 176Nm(130 lbf/ft).
REARSUSPENSION 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are tightened tothe correct torque. Nm Anti-roll bar - Strap nylocnuts 30 .............................................................................. - Ball linkself lock nut 68 ........................................................................ - Castellated nut 40 ................................................................................ Top linktomounting bracket 176 ..................................................................... Bottom linktoaxle 176 ..................................................................................... Bottom linktochassis 176 ............................................................................... Top linkbracket torear cross member 47 ...................................................... Shock absorber toaxle 37N ............................................................................
BRAKES1 DESCRIPTION ANDOPERATION DESCRIPTION The mechanical components ofthe hydraulic braking system consists offour piston caliper discbrakes at the front andtwopiston caliper discbrakes atthe rear. Vented frontbrake discsarefitted asstandard on 110/130 models,while90models havesoliddiscs. However, on90models withaheavy dutychassis, vented frontdiscs mayalsobefitted. A cable controlled parkingbrakeoperates asingle drum brake mounted onthe output shaftofthe transfer gearbox andiscompletely independent ofthe main braking system. The basic hydraulic systeminvolves 2separate and independent primaryandsecondary circuitswhich permits adegree ofbraking shouldafault occur in one ofthe circuits. Theprimary circuitoperates the rear brake calipers andthesecondary circuitthefront brake calipers. Master cylinder components 1. Secondary plunger 2. Secondary spring 3. Recuperation seal 4. Primary spring 5. Recuperation seal 6. Primary plunger
70BRAKES 2 DESCRIPTION ANDOPERATION OPERATION Master cylinder A tandem mastercylinder, whichisassisted byalight weight, short,compact servo,isfed byadivided fluid reservoir. Therear section supplies fluidforthe primary circuitandthefront section thesecondary circuit.When thebrakes areoff,the fluid canmove unrestricted betweenthedual linesystem andthe separate reservoirs inthe fluid supply tank. When thefootbrake isapplied, theprimary plunger assembly movesupthe cylinder boreandthe pressure createdactsinconjunction withtheprimary spring toovercome thesecondary springs,thus moving thesecondary plungerassembly upthe bore. At the same timeinitial movement ofboth plungers takes therecuperating sealspastthecut-off holesin the cylinder chambers Aand C, seeJ6321, and applies pressure tothe fliud inthose chambers, which is directed tothe respective circuits. The fluid inchambers Band Disunaffected by movement ofthe plungers andcanmove unrestricted between theseparate chambers andrespective reservoirs inthe fluid supply tank,bothbefore and during brakeapplication. Whenthebrakes are released, theplunger assemblies, aidedbythe return springs areretracted fasterthanthefluid; thiscreates a depression betweenthefluid inchambers Aand C and therecuperation seals. The recuperation sealsmomentarily collapseallowing fluid inchambers Band Dtoflow through theholes in the plungers, overthecollapsed sealsandinto chambers Aand Crespectively. Themovement of fluid from onesetofchambers tothe other, is compensated forbyfluid from theseparate reservoirs in the supply tankmoving through thefeed holes in the cylinder. Conversely, thefinal return movement of the plunger assemblies causestheextra fluidin chambers Aand Ctomove through thecutoff holes intothefluid reservoir. The servo unitprovides controlled powerassistance to tothe brake pedalwhenpressure isapplied. Power is obtained fromavacuum pumplocated onthe RH side ofthe engine cylinder block.Thevacuum is applied toboth sides ofaflexing diaphragm, andby admitting atmosheric pressuretothe rear diaphragm, assistance isobtained. Theservo unitismounted between thebrake pedalandmaster cylinder andis linked tothese bypush rods. Should avacuum failure occur, thetwo push rodswillactasasingle rod allowing thebrakes tofunction inthe normal way, although moreeffortwillberequired tooperate the brake pedal. Hydraulic system A brake fluidlossswitch isfitted tothe master cylinder reservoir fillercap. Theswitch iswired toawarning light onthe vehicle fasciaandwillilluminate asabulb check whentheignition isswitched onand extinguishes whentheengine isrunning andthe handbrake isreleased. Ahydraulic failureinthe system willresult influid loss, causing thewarning light toilluminate. On 90models apressure reducingvalve(PRV), fitted to the RH bulkhead inthe engine compartment, maintains thebraking balance, seeJ6322. Pressure to the rear calipers isregulated bythe PRV, thisvalve is of the failure by-pass type,allowing fullsystem pressure tothe rear brake calipers inthe event ofa front (secondary) circuitfailure. NOTE: Insome countries, apressure reducing valvemaybefitted to110 models to conform tolegal requirements.
BRAKES3 DESCRIPTION ANDOPERATION 90Models 110/130 Models Hydraulic system A -Primary circuit B -Secondary circuit C -Pressure reducingvalve(PRV) 1. LH rear brake caliper 2. Tconnector 3. RH rear brake caliper 4. Brake servo 5. Master cylinder andreservoir 6. LH front brake caliper 7. RH front brake caliper
BRAKES1 REPAIR GENERAL BRAKESERVICE PRACTICE Brake fluidprecautions WARNING: Donot allow brake fluidto come intocontact witheyes orskin. CAUTION: Brakefluidcandamage paintwork, ifspilled washoffimmediately with plenty ofclean water. CAUTION: Useonly correct gradeofbrake fluid. Ifan assembly fluidisrequired use ONLY brakefluid.DoNOT usemineral oil, i.e. engine oiletc. CAUTION: Thoroughly cleanallbrake calipers, pipesandfittings before commencing workonany part ofthe brake system. Failuretodo socould cause foreign matter toenter thesystem andcause damage to seals andpistons whichwillseriously impairthe efficiency ofthe brake system. Toensure the brake system efficiency isnot impaired the following warnings mustbeadhered to:- DO NOT useanypetroleum basedcleaning fluids orany proprietary fluidscontaining petrol. DO NOT usebrake fluidpreviously bledfrom the system. DONOT flush thebrake system withanyfluid other thantherecommended brakefluid. The brake system shouldbedrained andflushed at the recommended serviceintervals. Cover allelectrical terminals carefullytomake absolutely certainthatnofluid enters the terminals andplugs. FLUID LEVEL CHECK/TOP UP WARNING:Cleanreservoir bodyandfiller cap before removing cap.Useonly fluid from asealed container. 1. Park vehicle onlevel ground. 2. Check levelisbetween MINandMAX marks. 3. Iflevel isbelow MINmarktopupfluid level to MAX markonreservoir, usingcorrect fluid. See LUBRICANTS, FLUIDSANDCAPACITIES, Information, Recommended lubricantsand fluids CAUTION: Donot fillreservoir above maximum line.
70BRAKES 2 REPAIR BRAKE SYSTEM BLEED Service repairno-70.25.02 Preparation WARNING: Beforebleeding thebrake system refertogeneral brakeservice practice. See General BrakeService Practice . During bleedprocedure, brakefluidlevel must not beallowed tofall below theMIN level. Tobleed thehydraulic circuits,fourbleed nipples areprovided, oneateach caliper. There aretwo methods bywhich aircan be removed fromthebraking system:- 1. MANUAL BLEEDPROCEDURE. 2. PRESSURE BLEEDPROCEDURE. Pressure bleedprocedure Purpose designed equipment forpressure fillingand bleeding ofhydraulic systemsmaybeused onLand Rover vehicles. Theequipment manufacturers instructions mustbefollowed andthepressure must not exceed 4.5bar, 65lb/in 2 . Manual bleedprocedure Equipment required CleanglassreceptacleBleed hoseWrenchApprox 2litres (3pints) brake fluid.See LUBRICANTS, FLUIDSANDCAPACITIES, Information, Recommended lubricantsand fluids Master cylinder bleed 1. Disconnect battery. 2. Depress brakepedalfullyandslowly 5times. 3. Release thepedal andwait forten seconds. 4. Air bubbles willrise intothereservoir during these instructions. 5. Repeat instructions untilafirm resistance isfelt at the pedal. Complete circuitbleed 1. Disconnect battery. 2. Bleed frontcalipers, driverssidefirst. Fitbleed hose tobleed screw. 3. Dip free endofbleed hoseintobrake fluidin bleed bottle. 4. Open bleedscrew ofcaliper. 5. Depress brakepedalfullyseveral timesuntilfluid is clear ofair bubbles. 6. Keeping pedalfullydepressed, tightenbleed screw, thenrelease pedal. 7. Repeat procedure onother frontcaliper followed by rear calipers. 8. Fitallbleed screw protection caps. 9. Check/top-up fluidlevel when bleeding is complete See Fluid Level Check/Top-Up.
BRAKES3 REPAIR MASTER CYLINDER Service repairno-70.30.08 Before starting repairrefertogeneral brakeservice practice See General BrakeService Practice. Remove 1. Disconnect battery. 2. Place acontainer underthemaster cylinder to catch escaping brakefluid. 3. Clean arearound master cylinder ports. 4.Disconnect pipesfrommaster cylinder ports. Cover, notplug, thepipe ends toprevent entryof dirt. 5. Disconnect electricalleadsfromreservoir cap. 6. Remove twonuts securing mastercylinder to servo andwithdraw cylinder. 7. Remove reservoir capand drain fluidinto suitable container fordisposal. 8. The reservoir isapush fitin the master cylinder and secured byseals. Carefully easethe reservoir fromthemaster cylinder byrolling it from theseals. Notethatthetwo seals are different sizes. Refit 9. Insert newreservoir sealsinthe master cylinder ports andfitreservoir tomaster cylinder. 10. Ensuring thatwater ingress sealisin position, fit master cylinder toservo. Tighten fixingsto 26 Nm (19lbf/ft). 11. Connect brakepipestomaster cylinder ports and tighten to 15Nm (11lbf/ft). 12. Fitelectrical leadstoreservoir cap 13. Fillreservoir withrecommended brakefluid. See LUBRICANTS, FLUIDSANDCAPACITIES, Information, Recommended lubricantsand fluids 14. Bleed thebrake systemSeeBrake system bleed . 15. Reconnect batteryandroad testvehicle.
70BRAKES 4 REPAIR PRESSURE REDUCINGVALVE(PRV) Service repairno-70.25.21 Remove 1. Disconnect battery. 2. Clean areaaround reducing valveports. 3. Place acontainer undervalvetocatch escaping brake fluid. 4.Disconnect primarycircuitpipeunions ñAñ from valve. 5. Disconnect secondarycircuitpipeunions ñBñ from valve. 6. Cover pipestoprevent ingressofdirt. 7. Remove singleretaining nutand boltsecuring valve toengine bulkhead. 8. Remove valve. Refit 9. Fitvalve toengine bulkhead. Tightenboltto 15 Nm (11lbf/ft). 10. Connect primaryandsecondary circuitpipesto valve. Tighten to 16Nm (12lbf/ft). 11. Fillbrake reservoir withrecommended brake fluid See LUBRICANTS, FLUIDSAND CAPACITIES, Information,Recommended lubricants andfluids . 12. Bleed thebrake system SeeBrake system bleed . 13. Reconnect batteryandroad testvehicle. SERVO NONRETURN VALVE Service repairno-70.50.15 Remove 1. Disconnect brakevacuum hosefromservo non return valve. 2. Carefully prisevalve outwith ascrewdriver blade between valveandgrommet. Takecarenotto exert toomuch pressure onthe vacuum chamber. 3. Remove rubbergrommet butbecareful notto allow itto fall into thevacuum chamber. 4. Check thevalve forcorrect operation; itshould not bepossible topass airthrough intotheservo in direction ofarrow. Donot use compressed air. Refit 5. Fitrubber grommet. 6. Smear ribsofthe valve withLucas Girling rubber grease toassist assembly, andpush valve fully home. 7. Connect vacuumhosetothe valve. 8. Road testvehicle.