Defender 90 / 110 / 130. Instruction - page 1

01

INTRODUCTION

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This Workshop Manual covers the Land Rover Ninety and One Ten range

of vehicles. It is primarily designed to

assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to

completed within t h e time stated in the 'Repair Operation Times'.

The Manual has been produced in separate books; this allows the information to be distributed throughout the
specialist areas of

modern service facility.

A

table of contents in

Book 1 lists the major components and systems together with the section and book numbers.

The cover of each book details the sections contained within that book.

The title page

of each book carries the part numbers required to order replacement books, binders or complete

Service Manuals. This can be done through the normal channels.

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 o f replacement parts and

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 bc 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

than Land Rover parts.

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.

POISONOUS SUBSTANCES

Many liquids and other substances used in motor vehicles are poisonous and should under

no

circumstances be

consumed and should as far as possible be kept away from open wounds. These substances among others include
antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed if petrol (gasoline) 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.

GENERAL

vapour

is highly flammable and in confined spaces is also very explosive and toxic.

When

evaporates it produces

150

times its

own volume

in

vapour, which when diluted with air

readily be distributed throughout a workshop by air current, consequently, even a small spillage of

is

potentially very dangerous.

.

....

.

becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can

3

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Always have a fire extinguisher containing FOAM

GAS, o r POWDER close at hand when handling or draining

fuel, o r when dismantling fuel systems and

in areas

fuel containers are stored.

Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work

on a

system.

Whenever

is being handled, drained or stored, o r when fuel systems are being dismantled all forms of

ignition must be extinguished or removed, any

used must be flameproof and kept clear of spillage.

NO

O N E SHOULD BE PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL/

GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.

FUEL

TANK DRAINING

WARNING:

MUST NOT

BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST

IT

IS

STANDING OVER A PIT.

Draining or extracting

from vehicle fuel tank must be carried out in a well ventilated area.

The receptacle used to contain the

must be more than adequate for the full amount of fuel to

extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area
which meets the requirements of local authority regulations.
WHEN

HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK THE

PRECAUTIONS GOVERNING NAKED LIGHTS

AND IGNITION SOURCES SHOULD BE MAINTAINED.

FUEL

TANK

REMOVAL

On vehicles where the fuel line is secured

to

the fuel tank outlet by a spring steel clip, it is recommended that such

clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedure will avoid the
possibility of residual petrol fumes in the fuel tank being ignited when the clips are released.
As an added precaution fuel tanks should have a

VAPOUR warning label attached to them

as soon as they are removed from the vehicle.

FUEL

TANK

REPAIR

no circumstances should a repair to any tank involving heat treatment be carried out without first rendering

the tank SAFE, by using

of the following methods:

STEAMING: With the filler cap and tank unit removed, empty the tank. Steam the tank for at least two hours

with low pressure steam. Position the tank

so that condensation can drain away freely, ensuring that any

sediment and sludge not volatised by the steam, is washed out during the steaming process.
BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling

water containing

an

effective alkaline degreasing agent or a detergent, with t h e water filling and

also

surrounding the tank for at least two hours.
After steaming o r boiling a signed and dated label to this effect should be attached to the tank

SPECIFICATION

Purchasers arc advised that the specification details set out in this Manual apply to a

of

vehicles and not to any

one. For the specification of a particular vehicle, purchasers should consult their Distributor o r Dealer.

The Manufacturers reserve

right

to

vary their specifications 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

COPYRIGHT

Rover Limited 1984

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 Land

Rover Limited, Service Department, Solihull, England.

4

Special

Service

Tools

The use of approved special service tools is important. They are essential if service operations
are to be carried out efficiently, and safely. The amount

of time which 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.

where there is no distributor may order direct from V. L. Churchill Limited.

P.O.

Box

3, Daventry, Northamptonshire, England

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

or from Land Rover Ltd.,

under part number

from

following address, Land Rover Limited, Service Department,

Lode Lane,

Solihull, West Midlands, England B92 8NW.

5

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS

VEHICLE IDENTIFICATION NUMBER (VIN)

The

Vehicle

Identification

Number

and

the

recommended maximum vehicle weights are 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
Limited.

Key to Vehicle Identification Number Plate

A

Type approval

B VIN

(minimum

of

17

digits)

C Maximum permitted laden weight for vehicle

D

Maximum vehicle and trailer weight

E

road weight

-

front axle

F

Maximum road weight

-

rear axle

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ENGINE SERIAL NUMBER

-

ENGINE

The

engine serial number is stamped

on a cast pad

on

the cylinder block between numbers

3 and 5

cylinders.

6

ENGINE SERIAL NUMBER

-

4 CYLINDER

ENGINES

The 4 cylinder engine number is stamped on a
machined surface at the front left-hand side of the

O n later engines the number is stamped above the rear

side cover, as the second illustration shows.

engine adjacent to the exhaust manifold front flange.