Defender 90 NAS. Instruction - page 1





Many ’0’ ring seals, flexible pipes and other similar
items which appear to be natural rubber are made of
synthetic materials called Fluoroelastomers. Under
normal operating conditions this material is safe, and
does not present a health hazard. However, if the
material is damaged by fire or excessive heat, it can
break down and produce highly corrosive Hydrofluoric
acid which can cause serious burns on contact with
skin. Should the material be in a burnt or overheated
condition handle only with seamless industrial gloves.
Decontaminate and dispose of the gloves immediately
after use.

If skin contact does occur, remove any contaminated
clothing immediately and obtain medical assistance
without delay. In the meantime, wash the affected
area with copious amounts of cold water or limewater
for fifteen to sixty minutes.


A number of branded products are recommended in
this manual for use during maintenance and repair
These items include:

They should be available locally from garage
equipment suppliers.


WARNING: Prolonged and repeated
contact with engine or motor oil will result
in the removal of natural fats from the

skin, leading to dryness, irritation and dermatitis.

Used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities should be provided.

Handling precautions

1. Avoid prolonged and repeated contact with oils,

particularly used engine oils.

2. Wear protective clothing, including impervious

gloves where applicable.

3. Do not put oily rags in pockets.
4. Avoid contaminating clothes, particularly

underwear, with oil.

5. Overalls must be cleaned regularly. Discard

unwashable clothing and oil impregnated

6. First aid treatment must be obtained immediately

for open cuts and wounds.

7. Use barrier creams, before each work period, to

help the removal of oil from the skin.

8. Wash with soap and water to ensure all oil is

removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.

9. Do not use gasoline, kerosene, diesel fuel,

petrol, thinners or solvents for washing the skin.

10. If skin disorders develop, obtain medical advice.
11. Where practicable, degrease components prior

to handling.

12. Where there is a risk of eye contact, eye

protection should be worn, for example, goggles
or face shields; in addition an eye wash facility
should be provided.

Disposing of used oils

Environmental protection precaution

It is illegal to pour used oil onto the ground, down
sewers or drains, or into waterways.

Dispose of used oil through authorised waste disposal
contractors. If in doubt contact your Local Authority for
advice on disposal facilities.






DO NOT FIT unapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.


WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for

multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.


To prevent consequential rusting, any steam cleaning
within the engine bay MUST be followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine coolant pipes, hose clips and ignition
coil bracket.


The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any one. For the specification of a particular vehicle
purchasers should consult their Dealer
The Manufacturer reserve the 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

Whilst every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer or Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.


The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified, only these tools should be used
to avoid the possibility of personal injury or
damage to the components.
Also the amount of time
which they save can be considerable.

Every special tool is designed with the close
co-operation of Land Rover, 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. Countries where there is
no distributor may order direct from:
V. L. Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN11 4NF.

The tools recommended in this Workshop Manual are
listed in a multi-language illustrated catalogue,
obtainable from:
Messers. V. L. Churchill at the above address,
or from:
Land Rover Publications,
Charactor Mailing
Haysham Road,
Merseyside, L70 1JL,


' 1996 Rover Group Limited

All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Rover





The following instructions must be carried out before
raising the vehicle off the ground.

1. Use a solid level ground surface.
2. Apply parking brake.
3. Select ’P’ (Park) in main gearbox.
4. Select Low range in transfer gearbox.

CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be

adhered to.


Body structure
Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bell housing

Jack or support vehicle by axles only.

Vehicle jack

The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to
Owner’s Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.

Hydraulic jack

A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used, see J6083.

CAUTION: Do not commence work on the
underside of the vehicle until suitable
stands have been positioned under the


Raise front of the vehicle

1. Position cup of hydraulic arm under differential


NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the

ground as the rear axle has less sway stiffness.

2. Raise front road wheels to enable an axle stand

to be installed under left hand axle tube.

3. Position an axle stand under right hand axle

tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.





4. Before commencing work on underside of

vehicle re-check security of vehicle on stands.

5. Reverse procedure when removing vehicle from


Raise rear of vehicle

1. Position cup of hydraulic arm under differential


2. Raise vehicle to enable axle stands to be

installed under left and right hand axle tubes.

3. Lower jack until axle sits securely on axle

stands, remove trolley jack.

4. Before commencing work on underside of

vehicle re-check security of vehicle on stands.

5. Reverse procedure when removing vehicle from



Use only a ’drive on’ type ramp which supports vehicle
on its own road wheels. If a ’wheel-free’ condition is
required, use a ’drive on’ ramp incorporating a
’wheel-free’ system providing support beneath axle
casings. Alternatively, place vehicle on a firm, flat floor
and support on axle stands.


The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using ’Two Post’ ramps
employing four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If a vehicle is raised on a Two Post ramp,
responsibility for safety of the vehicle and
personnel performing service operations lies with
the Service Provider.


WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.

Four wheel dynamometers

Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.

Two wheel dynamometers

IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.

If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.

If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

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