Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							FUEL SYSTEM 
:.. 20. 
21. 
22. 
23. 
21. 
25. 
26. 
- 
19 3 
Disconnect the inter-connecting link between  the 
carburetters at the  left hand carburetter. 
At  the  right  hand carburetter,  release 
the lock nut 
and  slacken  off 
the lost motion adjustment  screw, 
until 
it is  well  clear of the spring loaded  pad. 
If  necessary  adjust the idle  screw  to 
maintain the 
correct  idle speed.  Check the 
CO level and 
carburetter  balance, adjust 
if required. 
Re
-connect  the inter-connecting  link to the  lcft 
hand  carburetter. 
Hold  the  right  hand  throttle lever against  the idle 
screw  stop and adjust  the lost  motion  screw  until 
contact  is made  with the spring  loaded  pad, tighten 
the lock nut. 
Check  the idle  speed  and balance.  Adjust  the lost 
motion  screw to restore balance 
if necessary. 
Ensuring  that the roller  is firmly  seated 
in the lower 
corner 
of the  cam  lever,  tighten  the nut which 
secures  the inter
-connecting  link  ball to  the cam 
lever. 
Fast idle adjustment 
27. 
28. 
29. 
30. 
31. 
32. 
33. 
34. 
35. 
Pull out the cold  start  control  (choke)  until the 
scribed  line on the 
lcft hand  fast  idlc  cam  is in-line 
with  the centre 
of the fast idle screw  head. 
Check  that the scribed  line  on the  right  hand  fast 
idle  cam  is similarly  in
-line with  the fast  idle  screw 
head. 
If there is mis-alignment,  slacken the fast idle 
cam  link  rod screw 
at the right  hand  carburetter 
and  move  the cam  until  the scribed 
line coincides 
with  the centre  of 
thc screw head. Tightcn thc cam 
rod  screw. 
Turn the  fast  idle  screw  clockwise,  on each 
carburetter,  until just clear 
of the cam. 
Turn the  fast  idlc  screw  of the leading  (left-hand) 
carburetter  down (clockwise)  until 
a slight change 
in engine speed  is noted. 
Similarly  turn the fast  idle  screw  of the  second 
carburetter  (right
-hand) down until a further  slight 
change 
of engine speed  is noted. 
Adjust  the  fast  idle screws of both  carburetters  by 
equal  amounts 
to achieve  a fast  idle  speed of 1100 
to 1150 revhin. 
Tighten  the  fast  idle screw lock-nut on both 
carburetters.  Push 
the cold start  (choke)  fully 
home 
then pull it out  again to its full cxtent and 
re
-check  the fast idle  speed. 
Fit the appropriate  blanking plug and cap to the 
mixture  screw recess  and idle adjusting screw. 
Fit  the  Carburetter  air  intake elbows and  air 
cleaner. 
.. 
11  
						

							STEERING 
Special tools: 
Drop arm puller 
MS 252A 
End  cover  wrench  adaptor 
LST123 Input shaft oil seal installer LST124 
Sector  shaft oil seal installer LST125 
Valve  seal installer and valve ring compressor LST126 
Preload setting  tool R01016 
57 
Dismantle 
1. Remove the steering box from the vehicle. 
2. Bend  back the locking  tab and removc the  drop 
arm  nut.  Using  special 
tool MS 252 A or a suitablc 
alternative,  withdraw the drop  arm from  the sector 
shaft. 
3.  Using  special  adaptor  tool 
LST123 turn the 
cylinder cover anti-clockwise  to expose  end of the 
locking  ring. Now  turn the cover  clockwise  to 
extract  the ring. T 
5. Slacken the grub  screw  securing  the rack  pad 
adjuster. 
4. To  remove  the cover,  turn the input  shaft to the left 
lock for a LHD drive  steering  box or to the right 
for a RHD drive  steering box until the rack  piston 
pushes  the cover  out 
to enable it to be  withdrawn 
by  hand. 
ST 
6. With  a screwdriver  remove the rack  pad adjuster, 
‘0’ ring and spring. 
continued 
13  
						

							El STEERING 
7. Restrain  the  sector  shaft  adjuster with a 6 mm 
8. Remove the six bolts  securing the sector  shaft 
hexagonal 
key and  remove  the locknut. 
cover. 
ST1816M 
9. Hold  the  sector shaft  cover  and turn  the  adjuster 
and  screw  clockwise 
until the cover  can  be 
removed. 
10. Lift-out the sector shaft. 
11. Remove  the rack  and  piston  assembly and collect 
the rack adjuster  thrust pad. 
ST1819M 
g.2 -- 
% *’ 12. Drive-out the worm  adjusting  screw locking pin. 
13.  Using  special  tool 
LST123, remove the input shaft 
worm  adjusting  screw anti
-clockwise. 
14. Tap the splined  end of the input shaft to free  the 
outer  bearing.  Remove 
the bearing  track  and ball 
cage  assembly. 
ST1818M 
14  
						

							STEERING 
,..’ - 15. Withdraw the mput shaft, worm and valve 
assembly. 
15 
ST1822M 
16. Release  the circlip  and remove  the  steel  washer 
and  oil seal  from the  sector shaft housing. 
oil  seal  from 
thc input  shaft housing. 
-. 17. Remove the  wire circlip, anti-extrusion washer  and 
17 
ST1949M 
INSPECTION AND OVERHAUL OF COMPONENTS 
Steering box housing 
1. 
2 
3. 
4 
Examine  the  sector  shaft  upper and lower  needle 
roller bcarings and if necessary drive  them  from the 
housing 
with a  suitable drift. 
Inspect  the  input shaft needle  bearing  and 
if worn 
drive 
it from  the  housing  and  press-in a 
replacement.  Examine the  piston 
bore for wear  and scores. 
Chcck the inp.1 shaft t?orcs for wear and scorcs. 
ST 
Sector  shaft assembly 
5. Chcck  that  no side play or wear exists in the roller. 
6. Check the condition of the adjustcr and  its retainer 
7. ‘The axial  clearancc of the adjustcr  should not 
8. Examinc the bearing  journals on the shaft for wear 
9. Check  the gcar teeth for excessive  and  uncvcn 
and 
that  the crimping 
is sound. 
exceed 
0,20 mm (0.008 in). 
and  damage. 
wear,  scores  and pitting. 
continued 
ST1954M  
						

							17 STEERING 
Valve and worm  assembly 
NOTE: If the  inner  ball race  is faulty  and unfit for 
further  service it cannot  be  renewed and a new  valve 
and  worm  assembly  must be obtained  and fitted.  Should 
this  be the 
case, the  following  checks of the  valve  and 
worm  can be ignored. 
10. Examine  the valve  rings which  must be free  from 
cuts,  scratches  and scores. 
Also, the rings  should 
be a  loose  fit 
in the grooves. 
11. If any  ring  is unsatisfactory,  all the  rings  must be 
renewed.  When  removing 
the rings take care  not to 
damage  the valve  grooves. 
12. To fit new rings use special  tool LST126, which 
consists  of the  following  three parts:
- 
a) Ring  expander. 
b)  Split  coller. 
c)  Ring  compressor 
Before  using the tool  lubricate  each  part with  the 
recommended power steering  fluid. 
13. Warm the five rings in hot water  leaving  them in 
the water  until ready  for fitting. When pliable, feed 
the  ring  for  the  lower  groove (nearest  the  roller 
bearing)  over 
the expander  and position  the 
expander  over 
the input  shaft,  slide the ring  into 
the groove  and mould it into  position  with the 
fingers. 
13 
A 
ST1941 M 
14. Encircle  the ring  with  the split  coller  and  squeeze 
the coller  together,  by hand,  and  hold  for 
approximately  thirty seconds. 
14 
/= . rh “7 15. Remove  the  split coller  and with  care,  case the 
compressor  tool over  the ring  and  leave  for  a few 
minutes 
to cool  before  carefully removing the tool. 
- 
E- ST1942M ?. __# 
16. Using  the  expander  tool, as before, fit the 
remaining  four rings,  one at a  time,  into  the 
grooves  and 
mould with the fingers. It is important 
that 
only one  ring  at a time  is placed on the 
expander  since 
in the meantime  the remaining 
rings  could cool  in an  expanded  condition making 
it 
difficult to locate and contract  the rings  in the  valve 
grooves.  Encircle the 
four rings with the split  coller 
and  squeeze  together 
for approximately  thirty 
seconds.  Then, with care,  ease the compression 
tool  over  the four  rings  and allow  to cool  for about 
five minutes  before  carefully  withdrawing the 
compressor. 
continued 
16  
						

							STEERING 
worm. 
b 
57 
10 17 21 
17 
18 20 19 
ST1955M 
22. 
The  valve  and worm  assembly  should be renewed if 
there  is wear  at the  following  points: 
a) Inner and outer  bearing  tracks. 
b)  Worm. 
c)  Valve  locator. 
d)  Input  shaft needle  bearing  journal. 
23. Examine  the outer  ball race  and track  for wear  and 
general  condition.  The race  should  be renewed 
if 
there  is wear  and pitting or if a new  valve  and worm 
assembly  is being  fitted. 
ST1957M 
27 
 
28 
4 
32. To fit a new  plastic  seal to the piston,  warm the seal 
in hot  water  and fit to the piston  groove.  Insert the 
piston 
in the  inverted  position i.e. piston  first into 
the  cylinder  and leave  to cool. 
Thrust 
pad and adjuster 
24.  Examine 
the thrust  pad for scores. 
25. Check  that the thrust  pad seat in the adjuster  is not 
26.  Check  that the thrust  pad spring  is not  broken. 
worn 
or scored. 
Rack and piston 
27.  Examine  the rack  teeth  for wear  and pitting. 
28.  Check  that the surface  on which  the thrust  pad 
bears  is not  worn  and scored. 
Sector shaft cover 
32 
33. Examine the sector  shaft cover  needle  bearing  and 
if necessary  extract the bearing  taking care not to 
damage the housing. 
con tinucd 
17  
						

							157 I STEERING 
34. Drive-in a new  bearing,  up to the shoulder,  with 
the  bearing  number  and chamfered  ends 
of the 
rollers  trailing. 
35. Fit a new ‘0’ ring seal to the cover. 
36. Check  that  the  cover bearing  lubrication  passage 
and  bleed nipple  hole is clear. 
ST 1 
Assemble 
During  the  following  assembly  instructions absolute 
cleanliness  must  bc observed. 
Also when  fitting 
components  and oil seals  they  must 
only be lubricated 
with the  recommended  fluid, or petroleum jelly. 
1. If removed, fit the sector  shaft  lower  needle 
bearings,  numbers outwards, 
to the steering  box to 
just  below  the chamfer. 
ST1931M 1 
2. Fit the  sector  shaft upper  needle bearings, number 
outwards, up 
to the shoulder 
.‘. 
Fitting  the valve and worm  assembly (input shaft) %+ * 
3. Fit the input  shaft  to the  steering  box housing  and 
lubricate  with the  recommended  fluid. 
Turn the 
shaft  to 
thc straight  ahead position. 
3 
4. Fit the input  shaft outer  bearing and track. 
5. Lubricate  and fit the input shaft cover  and ‘0’ ring 
seal using special tool LST123. 
ST1934M 
18  
						

							ST1935M /’ 
6. Secure preload  setting tool R01016 to the  input 
shaft  with the grub  screw.  Wind string  round  the 
tool  and tie a spring  balance  to the 
free end  of the 
string.  Whilst  turning  the input  shaft cover 
clockwise,  pull the spring  balance  until a constant 
preload  reading 
of 0,69 Nm is achieved. 
Fitting sector shaft and piston
-rack assembly 
7. Fit  the  sector  shaft to the  housing  and engage  it 
with  the input  shaft worm  in the  straight 
ahcad 
position. 
8. Screw-on, to the sector  shaft adjuster,  the sector 
shaft  cover  and secure  with two or three 
of the  six 
retaining  screws. 
9. Turn the adjuster  screw clockwise,  with a 6 mm 
hexagonai key, uniii the sector shaft ;US! makes 
contact  with the input  shaft worm. 
ST1937M 
10. Without  moving the adjuster, fit the  locknut  whilst 
restraining  the adjuster  screw with the 
6 mm key 
and  just  nip the locknut  with an open
-ended 
spanner. 
ST 1938M 
11. Temporarily fit the  drop  arm and tighten  the 
locknut  until no clearance  is 
felt between the sector 
shaft  and drop  arm. 
12. Rotate  the input  shaft one turn  clockwise,  then 
turn  the shaft  back to the  straight  ahead position 
whilst noting the point  at which  the backlash to the 
drop  arm disappears 
or is ‘taken-up’. 
anti-cbckwise on  to ihc Uppesitc lock. 
13. Repeat  instruction 12 and rotate  the input  shaft 
19  
						

							157 I STEERING 
18. Lubricate the rack piston  plastic  seal and insert  the 
piston  into the piston  bore, rack end first,  as 
in 
instruction 11 of the  dismantling  procedure, to a 
depth  of 37 
mm below the lip of the  bore. 
19. Lubricate  and fit the  sector  shaft in the straight 
ahead  position. 
20.  Lubricate  and 
fit ‘0’ ring seal to the sector  shaft 
cover. 
21.  Restrain  the sector  shaft adjuster  and screw
-on the 
cover,  reversing instruction 17. Secure with the six 
bolts,  tightening  evenly  to  25 
to 30 Nm (18 to 
22  Ibs  ft). 
22.  Restrain  the  sector  shaft  adjuster and 
fit and 
tighten the  locknut, as instruction  10. 
23. 
Fit and  lubricate  an ‘0’ ring seal to the  rack 
adjuster  screw. 
24. 
Fit the  rack  pad and  spring  noting that the  larger 
flat side  of 
the pad is towards the rack. 
13. If  the  difference between  the  two points  at which 
the  backlash  is ‘takcn
-up’ or disappears is greater 
than 
90” (%of a  turn) it will  be necessary  to change 
the  shimming  behind the input  shaft  inner  bearing 
cup. 
15.  If the  shimming  requires adjustment, add a  shim 
on 
right-hand drive  steering  boxes if backlash  starts 
too  quickly  on clockwise  rotation. Should backlash 
start too quickly for anti-clockwise  rotation, 
remove a  shim. 
For a left-hand  drive  steering box, 
reverse  the foregoing  procedure. 
NOTE: If it is necessary  to perform  instruction 15, 
instructions 3 to 13 must be repeated  afterwards. 
16. Remove  the drop  arm and whilst  restraining  the 
sector  shaft adjuster, 
so that it does not turn, 
remove 
the locknut. 
17. Remove  the  sector  shaft  cover screws and while 
ST 1944M 
25. Screw-in the  rack  pad adjuster  until the head is 
4 mm from the steering  box face. 
still  restraining  the  adjuster,  unscrew clockwise, 
the  cover 
from the sector  shaft  and  withdraw  the 
sector  shaft. 
I /I ’ ST1943M 
20