Defender (1993+). Manual — part 1

INTRODUCTION

01

INTRODUCTION

This Workshop Manual covers

the

Land Rover Defender One Ten vehicles.

It

is primarily

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

Individuals who undertake their own repairs should have some skill and training,

and

limit repairs to

components which could not affect the safety of the vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes, or suspension should

be

carried out

by a Land Rover

Dealer. Repairs to such items should NEVER be attempted by untrained individuals.

WARNINGS and CAUTlONS are given throughout this Manual in the following form:

WARNING: Procedures which must be followed precisely to avoid the possibility

of personal injury.

CAUTION: This calls attention to procedures which must be followed to avoid damage to Components.

NOTE: This calls attention to methods which make a

job

easier to

perform.

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 of replacement parts an
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 be 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 other than Land Rover parts.

All 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.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed

if

fuel

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.

Fuel vapor is highly flammable and in confined spaces is also very explosive and toxic.
When fuel evaporates

it

produces

150

times its own volume

in

vapor, which when diluted with

air

becomes

a

readily ignitable mixture. The vapor

is heavier than air and

will

always fall to the lowest level.

It

can readily be

distributed throughout a workshop by air current, consequently, even a small spillage of fuel is very dangerous.

designed

to

assist

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1993

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INTRODUCTION

Always have a fire extinguisher containing FOAM

CO

GAS,

or

POWDER close at

hand

when handling or

2

draining fuel, or when dismantling fuel systems

and

in areas where fuel containers are stored.

WARNING: It is imperative that the battery is not disconnected during fuel system repairs as arcing at
the battery terminal could ignite fuel v a p o r in the atmosphere. Always disconnect the vehicle battery
BEFORE carrying out work on a fuel system. Whenever fuel is being handled, transferred or stored, or
when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any
lead-lamps used must be flameproof and kept clear

NO ONE SHOULD BE PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH FUEL WITHOUT
FIRST HAVING HAD SPECIALIST TRAINING.

HOT FUEL HANDLING PRECAUTIONS
Before commencing any operation requiring fuel drainage from fuel tanks, the following procedures
should

be adhered to:

1.

Allow sufficient time for the fuel to cool, thus avoiding contact with hot fuels.

2. Vent system by removing the fuel cap

in

a well ventilated area replace cap until commencement

of tank drainage.

3. Before disconnecting any part of the fuel system

it

is vital to remove dirt, dust and debris from

around components t o prevent ingress of foreign matter into the fuel system. Cover the tank
apertures after removal to prevent entry

of dirt a n d escape of fuel v a p o r s .

FUEL TRANSFER

WARNING: FUEL MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILE IT IS
STANDING OVER A PIT.

The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved
transfer tank must

be

used according to the transfer tank manufacturer’s instructions and local regulations,

including attention to grounding of tanks.

FUEL TANK REMOVAL
A fuel vapor label should be attached to the fuel tank upon removal from vehicle. ENSURE TANK IS
COMPLETELY DRAINED.

FUEL TANK REPAIR
Under no circumstances should a repair to any tank

be attempted.

RECOMMENDED SEALANTS

A number

of branded products are recommended in this manual for use during maintenance and repair work.

These items include: HYLOMAR GASKET AND JOlNTlNG COMPOUND and HYLOSIL RTV SILICON

COMPOUND. They should

be available locally from garage equipment suppliers.

If

there is any problem

obtaining supplies, contact one

of

the following companies for advice and the address of the nearest stockist.

Marston Lubricants Limited

Hylo House

Prudhoe

Cale

Lane, New Springs

Northumberland

Wigan, WN2

1JR

NE42 6NP

Tel:

0942 824242

Tel:

0661

32014

Fax: 0942

826653

Fax: 0661 35839

Telex:

67230

Northern Adhesives Limited

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1993

INTRODUCTION

POISONOUS AND DANGEROUS SUBSTANCES
Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances

be consumed and should be kept away from open wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer additives, air conditioning refrigerant, lubricants and various
adhesives.

Engine oils

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading

to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminates which
may cause skin cancer. Adequate means of skin protection and washing facilities should be provided.

Health protection precautions

1. Avoid prolonged and repeated contact with oil particularly used engine oils.

2. Wear protective clothing, including impervious gloves where practicable.
3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly underpants, with oil.
5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear.

t aid treatment should be obtained immediately for open cuts and wounds.

barrier creams, applying before each work period, to help the removal of oil from the skin.

h with soap and water to ensure all oil is removed (skin cleaners and nail brushes will help).

Preparations containing lanolin replace the natural skin oils which have been removed. Do not use
petrol, kerosene, Diesel fuel, gas oil, thinners or solvents for washing skin.

9. If skin disorders develop, obtain medical advice immediately.

10. Where possible, degrease components before handling.
11. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or

face shields. In addition, an eye wash facility should be provided.

Asbestos
Some components on the vehicle, such as gaskets, brake and clutch linings and friction pads contain asbestos.
Inhaling asbestos dust is dangerous

to health and the following essential precautions must be observed.

1.

Work out of doors or

in a well ventilated area and wear a protective mask.

2. Dust found on the vehicle or produced during work should be removed by vacuuming and not blowing.

3.

Asbestos dust waste should be dampened, placed

in

a sealed container and labelled with what

it

contains

to

ensure safe disposal.

4.

If any machining, cutting of drilling is attempted on materials containing asbestos the item should be

dampened and only hand

tools or low speed power tools used.

Synthetic rubber
Many “O” ring seals, flexible pipes and other similar items which appear to be natural rubber, are, in fact, 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 heating, it can break

down and produce highly corrosive Hydrofluoric acid which can cause serious bums on contact with skin.
Should the material be in a burnt or over heated 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.

DISPOSING OF USED

OILS AND FLUIDS

Environmental protection precaution

It is illegal to pour used oil and other fluids onto the ground, down sewers or drains, or into waterways.
Dispose of used oil through authorized waste disposal contractors.

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INTRODUCTION

ACCESSORIES AND CONVERSIONS
Land Rover vehicles are designed and constructed for a variety of uses but no alterations or conversions

should be carried out to any vehicle produced by Land Rover which could affect the safety of the vehicle or its
passengers.

Land Rover has tested and approved a large number of accessories and conversions, suitable for all models.
Before fitting any accessory or commencing any conversion work to any Land Rover vehicle, check that the

accessory or conversion is approved by Land Rover.

WARNING: DO NOT

FIT unapproved accessories or conversions, as they could affect the safety of the

vehicle. Land Rover

will not accept any liability for death, personal injury or damage

to

property which

may occur

as a direct result of fitment of non-approved accessories or the carrying out of

non-approved conversions to Land Rover vehicles.

SPECIFICATION
Purchasers are advised that the specification details set out in the Manual apply to a range of vehicles and not

to any one. For the specification of a particular vehicle, purchasers should consult their Distributor or Dealer.

The Manufacturers reserve the right to vary their specification 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 thereof.

COPYRIGHT

© Rover Group Ltd 1993

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
Rover Group Ltd.

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FEB 1993