Defender 90 / 110 / 130. Instruction - page 18
MAINTENANCE
CLEAN AND LUBRICATE LUCAS DISTRIBUTOR
1. Clean and lightly grease the cam with Shell Retinax
o r equivalent and remove any surplus lubricant.
2.
Using the same grease lubricate the underside of
the heel actuator.
3. Grease the actuator ramps and contact breaker
heel ribs.
4. Apply grease to the fixed pin and the actuator fork.
5.
Apply a drop
of clean engine oil to the felt pad
the rotor arm.
6.
Every
40.000
(25,000
miles) lubricate the
automatic advance mechanism
by injecting one
or
two drops
of engine oil through the aperture in the
base plate.
7. Wipe the internal and external surfaces of the
distributor cap with clean dry nap-free cloth and fit
the cap to the distributor body.
3
2
ST
CHECK AND ADJUST
ENGINE DISTRIBUTOR
TIMING
Using Electronic Timing Equipment
A pointer on the timing cover and marks on the
crankshaft pulley indicate positions around
T.D.C.
on
No.
1 cylinder (i.e. front cylinder on left-hand bank).
Refer to 'Engine Tuning data' for appropriate ignition
timing.
Engine speed accuracy during ignition timing
is
important. Any variation from the required idle speed,
particularly in an upward direction, will lead to wrongly
set ignition timing.
1. Connect a stroboscopic timing light as instructed by
the manufacturer. The engine is timed on
No. 1
cylinder.
2 . Run the engine at idle speed.
3. Position the timing light to illuminate the
crankshaft pulley and scale.
WARNING: Ensure that personnel and equipment
are kept clear of the rotating cooling fan while using
the
timing light.
.
4. If the timing is correct the pulley mark indicated in
the Tuning Data will show. If correct, instruction
5
may be ignored.
5.
With the engine still running at idle speed, slacken
the clamp bolt and carefully rotate the distributor
body as required until the correct pulley mark
shows. Turn anticlockwise to advance and
clockwise to retard.
6. Tighten the clamp bolt with the unit in this
position.
20
MAINTENANCE
CLEAN, ADJUST
OR
RENEW SPARK PLUGS
Refit or renew spark plugs
.
.
1. Withdraw the
H.T.
leads from the spark plugs by
2. Using an appropriate plug spanner, remove the
gripping the shrouds, do not pull on the leads.
spark plugs.
11.
Check that the washers are fitted to the plugs.
12. It
important that only spark plugs specified in
Data section are used for replacements.
13. Incorrect grades
of plug may lead to piston over-
heating and engine failure.
14. Wash new plugs in petrol to remove the protective
coating, then set the electrode gaps to the
appropriate figures given in ‘Engine Tuning data’.
15.
Fit the plugs and washers to the engine but do not
overtighten.
16. Examine high tension leads, including the coil to
distributor lead, for insulation cracking or
corrosion at end contacts. Fit new leads as
necessary.
17. In addition to correct firing order, high tension
leads must be fitted in correct relation to each
other to avoid cross firing, as illustrated. This is
particularly important on the V8 engine.
First illustration. 4-cylinder engine.
Second illustration.
engine.
shrouds are firmly seated on plugs.
Clean and set gaps
18. When pushing leads on plugs ensure ferrules within
3.
Fit plug in plug cleaning machine.
4. Wobble plug with circular motion while operating
abrasive blast for
a maximum of four seconds.
CAUTION: Excessive abrasive blasting will erode
insulator nose.
5. Change to air blast only and continue to wobble
plug for a minimum of thirty seconds to remove
abrasive grit from plug cavity.
6. Wire-brush plug threads, open gap slightly.
7. Using point file, square off electrode surfaces.
8. Set electrode gap,
see ‘Engine Tuning data’,
9.
Test plugs in accordance with cleaning machine
manufacturer’s instructions. If satisfactory, refit
plugs in engine.
10.
If no machine is available carefully wire brush
electrodes and blow or wash away carbon particles.
Illustration shows:
A.
Dirty o r unsatisfactory electrode
Filing plug electrodes
C.
A
clean
plug correctly set
A
B
C
21
MAINTENANCE
CLEAN
AND TEST HEATER PLUGS
-
Diesel
CHECK BRAKE FLUID RESERVOIR
engines
REMOVE THE PLUGS
1. Check the fluid level in the fluid reservoir by
observing the level in relation to the
or
‘MAX’
marks on the side of the translucent
reservoir.
2. If the level is below the
‘MAX’
mark clean the
outside of the filler cap and top-up with new, clean
fluid from a sealed container. Use only fluid
recommended in the ‘General specification data’
section. Refit the cap.
1. Disconnect the battery.
2. Remove the terminal nut from each heater plug.
3 .
Detach the heater plug lead and washer from each
4.
Remove the heater plugs.
Clean and inspect
5.
Remove carbon from base of heater plugs to avoid
the possibility of short circuiting
of the element.
Do not sandblast.
6.
Examine the element for signs of fracture and
deterioration and the seating for scores. Plugs with
fractures or doubtful elements must be renewed.
Where scoring of the seating may impair the
sealing, the plug should be renewed.
Test and refit
7.
Test the plug internal circuit for continuity by
connecting it in circuit with a 12 volt side lamp bulb
open circuit is indicated and the heater plug must
be renewed.
and a 12 volt supply. If the bulb does not light an
ST 1088M
8. Ensure that the terminals are clean and that the
thread at the base
of the plug is free from carbon.
9. Fit the heater plugs to the engine.
Do
not
overtigh ten.
10.
Fit the heater plug lead and washer to each plug.
11.
Connect the battery.
CHECK CLUTCH FLUID RESERVOIR
1. Clean and remove the reservoir cap and observe
the fluid level
in relation to the marks
on the side of
the reservoir.
2. Top-up if necessary with new, clean fluid from a
sealed
container
and
of
a
recommended
specification
-
see ‘General specification data’
section. Refit the cap.
22
,
,
I
-
CHECK POWER STEERING
FLUID RESERVOIR
.....
..
,
1. Clean and remove the reservoir cap and observe
the fluid level
in
relation to the mark
on
the side of
the reservoir.
2. If necessary top-up with a recommended fluid
-
see ‘General specification data’ section
-
until the
fluid is 12
in) above the filter. Refit the
cap.
CHECK
COOLING SYSTEM COOLANT
Refer to the ‘Cooling system’ section for details
of
anti-freeze and inhibitors and to the ‘General
specification data’ section for anti-freeze protection
quantities.
With a cold engine, the expansion tank should be
approximately half full.
WARNING:
Do not remove the filler cap when the
engine is hot because the cooling system is pressurised
and personal scalding could result.
To remove the filler cap, first turn it anti-clockwise
a quarter of a turn and allow all pressure to escape,
before turning further in the same direction to lift it
off.
When replacing the
cap it is important that it
is tightened down
not just to the first stop.
Failure to tighten the filler cap properly may result
in water loss, with possible damage to the engine
through overheating.
MAINTENANCE
BATTERY
Check Specific Gravity
T h e specific gravity of the electrolyte should be
checked using a battery hydrometer. The readings
should be as follows:
Temperate
climate
below
(80°F)
as
commissioned for service, fully charged 1.270 to 1.290
specific gravity.
As expected during normal service, three-quarter
charged 1.230 to
1.250 specific gravity.
If the specific gravity should read between 1.190 to
1.210, half-charged, the battery must be bench charged
and the electrical equipment in the car should be
checked.
Tropical climate above
(80°F) as commissioned
for service, fully charged 1.210 to 1.230 specific gravity.
As expected during normal service, three-quarter
charge 1.170 to 1.190 specific gravity.
If the specific gravity should read between 1.130 to
half-charged, the battery must be bench charged
and the electrical equipment
on the car should be
checked.
Check and Top-Up Electrolyte Level
1. Wipe all dirt and moisture from the battery top.
2. Remove the filler cover. If necessary add sufficient
distilled water to raise the level to the top
of
separators.
Replace the filler plugs or manifold lid.
3 . Avoid the use of a naked light when examining the
4. In hot climates it will be necessary to top up the
battery at more frequent intervals.
5 .
In very cold weather it is essential that the vehicle
is used immediately after topping up, to ensure that
the distilled water is thoroughly mixed with the
electrolyte. Neglect of this precaution may result in
the distilled water freezing and causing damage to
the battery.
Battery terminals
6 . Remove battery terminals, clean, grease and refit.
7 .
Replace terminal screw; d o not overtighten.
Do
not use the screw for pulling down the terminal.
8. Do
N O T disconnect the battery cables while the
engine is running or damage to alternator
semiconductor devices may occur. It
also
inadvisable
to
break or make any connection
in the
alternator charging and control circuits while the
engine is running.
9. It is essential to observe the polarity of connections
to the battery, alternator and regulator, as any
incorrect connections made when reconnecting
cables may cause irreparable damage to the
semiconducto devices.
IMPORTANT NOTE: If a new battery is fitted
the
vehicle, it should be the same type as fitted to the vehicle
when new. Alternative batteries may vary in size
and
terminal positions and this could be a possible fire
hazard if the terminals or leads come into contact with
the battery clamp assembly. When fitting a new battery
ensure that the terminals and leads are clear of the
battery clamp assembly.