Land Rover Defender Workshop 1993 Rover Manual
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SUSPENSION LEVELLING UNIT Functional check A Boge Hydromat levelling unit is located in the centre of the rear axle. When the vehicle is unladen the levelling unit has little effect. The unit is self -energising and hence the vehicle has to be driven before the unit becomes effective, the time taken for this to happen being dependant upon the vehicle load, the speed at which it is driven and the roughness of the terrain being crossed. If the vehicle is overloaded the unit will fail to level 6. Load weights to the value of 650 kg evenly fully and more frequent bump stop contact will be over the rear load area of the vehicle and noticed. leave it to settle undisturbed for minimum Should the vehicle be left for a lengthy period e.g. period of thirty minutes. overnight, in a laden condition, it may settle. This is 7. With the driving seat occupied or with an due to normal internal fluid movement in the unit and approximate equivalent weight of 75 kg check is not detrimental to the unit performance. the bump stop clearance and note the Before carrying out he checks below, verity that the measurement. vehicle is being operated within the specified 8. Drive the vehicle on a test route maximum loading capabilities. If the levelling unit is approximately 5 km in length over undulating then believed to be at fault, the procedure below roads or graded tracks. At the completion of should be followed. the drive bring the vehicle to rest by light Whilst slight oil seepage is permissible, the unit brake application so as not to disturb the should be renewed if there is an excessive oil leak. vehicle loading. 9. Without disturbing the vehicle load and with 1. Remove excessive mud deposits from the driving seat occupied, check the bump underneath the vehicle and any heavy items stop clearance and note the reading, which from inside the vehicle that are not part of the must be in excess of 45 mm (average). original equipment. 10. Subtract the reading obtained under 2. Measure the clearance between the rear axle Instruction 7 from that obtained under bump pad and the bump stop rubber at the Instruction 9. If the change in clearance is in front outer corner on both sides of the vehicle, excess of 10 mm the levelling unit is dimension A. The average clearance should functioning correctly. be in excess of 67 mm. 11. If the figures obtained in instructions 9 and 10 3. If the bump stop clearance is less than the do not exceed 45 mm and 10 mm respectively above figure remove the rear springs and unload the vehicle and renew the levelling check the free length against the following unit. data in the chart. 4. Renew any spring where the free length is more than 20 mm shorter than the figures in the chart. 5. Having refitted or renewed any springs repeat the clearance check as described above. If the average bump clearance is still less than 67 mm renew the levelling unit. LAND ROVER COIL SPRING SPECIFICATION PART NO. DESCRIPTION COLOUR CODE LOCATION SPECIFICATION FREE LENGTH NRC 6388 Drivers Blue Stripe Rear Suspension 420 mm NRC 7000 Passengers Green & White Rear Suspension 400 mm Levelled Levelled Levelled Stripes Levelled
SUSPENSION REMOVE LEVELLING UNIT SPRINGS AND SHOCK ABSORBERS WARNING: The levelling unit contains Remove rear springs pressurised gas and must not be dismantled nor 1. Slacken the rear road wheel nuts and raise the casing screws removed. Repair is by the rear of the vehicle and lower the chassis replacement of complete unit only. on the axle stands or similar supports and remove the road wheels. 1. Raise and support the vehicle under the 2. Support the weight of the axle with a jack. 3. Disconnect the shock absorbers at the lower chassis and use a jack to support the weight of the axle. end. 2. Disconnect the upper links at the pivot 4. Remove the spring retainer plate. bracket. 5. Lower the axle sufficiently to withdraw the 3. Ease up the levelling unit lower gaiter and spring, but take care not to stretch the flexible unscrew the lower ball joint at the push rod brake hose by lowering the axle too far. using thin jawed spanners. 6. Remove the spring pan. 4. Release the webbing strap from the chassis. 5. Remove the four nuts securing the top bracket Fit rear springs to the chassis and withdraw the levelling unit complete with bracket. 7. Fit the spring pan and retainer plate. 8. Fit the spring into the chassis top location and using a turning motion fit the spring to the Renew levelling unit ball joints axle pan. 9. Secure the shock absorbers with the rubbers The ball joints for the levelling unit may be correctly located. dismantled for cleaning and examination. 10. Remove the axle support, fit the road wheels 6. Unscrew the lower ball joint from the pivot and lower the vehicle to ground. bracket. 11. Finally tighten the road wheel nuts. 7. Unscrew the ball joint from the top bracket. 8. Reassemble the ball joints, packing with Remove shock absorbers Dextagrease G.P. or equivalent or if 12. Slacken the road wheel nuts, raise the rear of necessary renew the joints if worn. the vehicle and support it under the axle and 9. Check the condition of the gaiters and renew remove the road wheels. if necessary. 13. Remove the shock absorber upper and lower retaining nuts and rubbers. Fit levelling unit 14. Remove the shock absorber from the top locating shaft and withdraw it from the vehicle. 10. Ensure the ball pin threads are clean and smear Loctite grade CVX on the ball pin Test shock absorbers threads. 15. Hold the shock absorber vertically in a vice, 11. Fit the upper ball joint to the levelling unit and secure the gaiter. 16. The shock absorber employs differential 12. Fit the top bracket complete with levelling unit damping having greater resistance on the to the chassis and secure with the four nuts extension stroke. Check operation by and tighten to 47 Nm. extending and compressing the shock 13. Fit the levelling unit to the lower ball joint and absorber. secure the gaiter. Resistance should be uniform throughout the 14. Attach the webbing strap to the chassis cross length of each stroke. If resistance is erratic member. or weak, renew the shock absorber. When 15. Fit the upper links to the pivot bracket and checking resistance a new shock absorber retain with the two bolts and nuts but do not may be used for comparison. To ensure that tighten at this stage. the new shock absorber IS primed, fully 16. Remove the jack in support of the axle and extend and compress the unit several times the support from under the chassis. before testing begins. 17. Allow the suspension to settle and then tighten the two bolts and nuts retaining the upper links to the pivot bracket to the correct 17. Fit the shock absorbers using new rubbers torque. and fit the lower rubbers and caps in the 18. Fit the road wheels, lower the vehicle and being careful not to damage the threads. Fit shock absorbers order illustrated. finally tighten the road wheel nuts.
SUSPENSION PAN HARD ROD RADIUS ARM Remove Remove 1. Remove fixings at mounting arm. 1. Loosen road wheel retaining nuts. 2. Remove fixings at axle bracket. 2. Raise front of vehicle. Support chassis on 3. Remove Panhard rod. stands and remove wheel. 4. Press out flexible bushes. Ensure the steel 3. Support front axle weight with jack. tubing locates on the outer edge of the bush and not on the rubber inner. 4. Remove radius arm to chassis side member fixings. 5. Disconnect track rod at ball joint. 6. Remove fixings, radius arm to axle. 7. Lower radius arm front end to clear axle and remove from vehicle. Refit 5. Fit replacement bushes. CAUTION: Apply pressure to outer edge of bush, and not rubber inner. 6. Reverse 1 to 4. Tighten fixings to 88Nm.
SUSPENSION 8. Press out flexible bushes. Refit 9. Press in replacement bushes. 7. Withdraw lower seating washer, rubber bush and cupwasher. 8. Remove fixings, shock absorber to mounting bracket. 9. Withdraw mounting bracket. 10. Lift off top seating washer, rubber bush and CAUTION: When pressing in new bushes press on outer edge of bush and not rubber inner. 10. Reverse 1 to 7. Tighten fixings to following torques: cupwasher. Radius arm to chassis 176Nm. Radius arm to axle 197Nm. Refit FRONT SHOCK ABSORBER 11. Reverse instructions 1 to 10. Remove 1. Loosen road wheel retaining nuts. 2. Support chassis on stands and remove road wheel. 3. Support axle weight with jack. 4. Remove shock absorber lower fixing and withdraw e cupwasher, rubber bush and seating washer. 5. Remove four shock absorber bracket fixings. 6. Withdraw shock absorber and bracket complete.
SUSPENSION FRONT ROAD SPRING BUMP STOP Remove Remove 1. Remove front shock absorber. 1. Remove fixings. CAUTION: Avoid over stretching brake hoses. If necessary loosen hose connector locknuts to allow hoses to follow axle. 2. Remove bump stop. 2. Lower axle sufficient to free road spring. 3. Withdraw road spring. 4. Withdraw shock absorber bracket securing ring. Refit 3. Position bolts in slots in chassis brackets. 4. Fit bump stop, secure with washers and nuts. Refit 5. Fit shock absorber bracket retaining ring. 6. Reverse 2 and 3. 7. Remove nut retaining securing ring. 8. Fit front shock absorber. Retain in position with a nut.
SUSPENSION ANTI-ROLL BAR ASSEMBLY KEY 1. Anti-roll bar 5. Nut and washer 2. Rubber bush 6. Castellated nut and cotter pin 3. Strap 7. Ball joint link arm 4. Nut, bolt, washer ANTI-ROLL BAR FRONT Refit Remove 4. Position bushes on anti-roll bar. Ensure split points towards axle. 1. Mark for reassembly position of rubber bushes 5. Fit anti-roll bar with two straps. To ensure on anti -roll bar. correct fit angled sides of bar should point 2. Remove four nuts, bolts and washers securing down as shown. Loosely fit the bolts, washers two bush straps. and nyloc nuts. 3. Remove nuts, bolts, washers and rubber 6. Fit bolt, washers and rubber bushes. Using bushes from ball joint links and remove new nuts fit anti -roll bar to ball joint links. anti -roll bar. Tighten to 68Nm. 7. Tighten nuts securing straps to 30Nm
SUSPENSION ANTI-ROLL BAR BALL JOINT LINKS Remove 1. Remove two nuts, bolts, washers and rubber bushes from ball joint links. 2. Remove cotter pin and loosen castellated nut a few turns. 3. Release ball joint using special tool 18G 1063A as shown. 4. Remove castellated nut and ball joint link. Refit 5. Fit ball joint link and castellated nut. Ensure ball joint link arm points up. Tighten to 40Nm and fit new cotter pin. 6. Align anti-roll bar to ball joint links. 7. Fit bolts, washers and rubber bushes using new self locking nuts secure anti -roll bar to ball joint links. Tighten to 68Nm.
BRAKING SYSTEM BRAKES DESCRIPTION The mechanical components of the Defender 90 braking system consists of four piston caliper disc brakes at the front and twin piston caliper disc brakes at the rear. The Defender 110 system consists of single cylinder drum brakes at the rear and four piston caliper disc brakes at the front. The cable controlled handbrake, common to both vehicles, is a mechanically operated single drum type brake mounted on the output shaft of the transfer box and is completely independent of the main braking system. Adjustment of all drum brakes is by a snail cam turned by a square peg on the back -plates. Caliper disc brakes are self adjusting. The basic hydraulic system involves two separate and independent primary and secondary circuits which permit a degree of braking should a fault occur in one of the circuits, The primary circuit A Right hand front brake operates the rear brakes and the secondary circuit B Left hand front brake controls the front brakes. The tandem master C Right hand rear brake cylinder, which is assisted by a type 80 direct acting D Left hand rear brake servo, is fed by a divided fluid reservoir. The rear E Jump hose section contains fluid for the primary circuit and the F LS.C. 80 servo and master cylinder assembly front portion supplies fluid for the secondary circuit. G G valve A brake fluid loss switch is fitted to the master cylinder filler cap. The switch is wired to a warning lamp bulb on the drivers control panel and the bulb will illuminate momentarily when the starter motor is actuated, indicating that the brake warning circuit is functioning correctly. A hydraulic failure in the primary or secondary circuits will result in fluid loss and cause the warning bulb to illuminate, in such an event, the driver must stop the vehicle immediately and investigate the cause. The G valve allows fluid to the rear brakes until a predetermined pressure is reached when the valve closes. The valve, from this point on, will only permit a proportion of any increase in fluid pressure to reach the rear brakes to prevent premature locking of the rear wheels. Should a failure occur in the front brake secondary circuit the design of the valve will ensure that the fluid to the rear brakes will by-pass the valve and allow full circuit pressure to the rear wheel cylinder.