Defender 90 / 110 / 130. Instruction - page 1
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.
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 to the
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
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.
The dimensions quoted are
design engineering specification. Alternative unit equivalents, shown
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
is essential that only Land Rover parts are used.
particularly drawn to the following points concerning repairs and the fitting o f replacement parts and
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.
Many liquids and other substances used in motor vehicles are poisonous and should under
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
of doubt appropriate enquiries should be made of
your local Fire Officer.
is highly flammable and in confined spaces is also very explosive and toxic.
evaporates it produces
vapour, which when diluted with air
readily be distributed throughout a workshop by air current, consequently, even a small spillage of
potentially very dangerous.
becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can
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
fuel containers are stored.
Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work
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.
O N E SHOULD BE PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL/
GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.
BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST
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.
HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK THE
PRECAUTIONS GOVERNING NAKED LIGHTS
AND IGNITION SOURCES SHOULD BE MAINTAINED.
On vehicles where the fuel line is secured
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.
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
effective alkaline degreasing agent or a detergent, with t h e water filling and
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
Purchasers arc advised that the specification details set out in this Manual apply to a
vehicles and not to any
one. For the specification of a particular vehicle, purchasers should consult their Distributor o r Dealer.
The Manufacturers reserve
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
of constant product improvement.
Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the
nor the Distributor or Dealer, by whom this Manual is supplied, shall in any circumstances be held
liable for any inaccuracy or the consequences
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
Rover Limited, Service Department, Solihull, England.
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
Every special tool is designed with the close co-operation
of Land Rover Ltd., and
put into production which has not been tested and approved by
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
All orders and enquiries from the United Kingdom should be sent direct to V.
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.
3, Daventry, Northamptonshire, England
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
following address, Land Rover Limited, Service Department,
Solihull, West Midlands, England B92 8NW.
LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS
VEHICLE IDENTIFICATION NUMBER (VIN)
recommended maximum vehicle weights are stamped
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
the spring mounting turret.
Always quote this number when writing to Land Rover
Key to Vehicle Identification Number Plate
C Maximum permitted laden weight for vehicle
Maximum vehicle and trailer weight
Maximum road weight
ENGINE SERIAL NUMBER
engine serial number is stamped
on a cast pad
the cylinder block between numbers
3 and 5
ENGINE SERIAL NUMBER
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.