Defender (1993+). Manual — part 6

TORQUE

WRENCH SETTINGS

REAR AXLE AND FINAL DRIVE

Nm

Crown wheel to differential case

. . . . . . . . . . ..

160

Rear cover to axle case

. . . . . . . . . . . . . ...

24

Ball joint mounting bracket to axle case

. . . . . . . ...

133

Drum to hub

. . . . . . . . . . . . . . . . . . .

18

Rear brake assembly and stub axle rear to axle

. . . . ..

65

Universal Joint flange

to

propeller shaft

. . . . . . . ...

47

Hub driving member to hub

. . . . . . . . . . . . ..

65

PROPELLER SHAFTS

Coupling flange bolts

. . . . . . . . . . . . . . ...

46

REAR SUSPENSION

Bottom link to chassis nut

. . . . . . . . . . . . .

176

Bottom link to mounting rubber

. . . . . . . . . . .

64

Top link bracket to chassis

. . . . . . . . . . . . ...

47

Shock absorber bracket to chassis

. . . . . . . . . ..

64

Anti

roll bar bush to chassis nuts

. . . . . . . . . . .

24

Upper link ball joint to axle castle nut

. . . . . . . . ...

176

Anti roll bar ball joint castle nut

. . . . . . . . . . .

40

Bump stop rubber bracket nuts

. . . . . . . . . . .

32

Shock absorber upper attachment to bracket

. . . . . ..

82

Shock absorber lower attachment nuts

. . . . . . . .

75

Tie bar to mounting arm nut

. . . . . . . . . . . . .

81

Mounting arm to chassis nuts

. . . . . . . . . . . ..

176

STEERING AND FRONT SUSPENSION

Tie bar to steering box nuts

. . . . . . . . . . . . .

81

Panhard rod to mounting arm nut

. . . . . . . . . .

88

Panhard rod

to

anchor bracket nut

. . . . . . . . . ..

88

Panhard rod mounting bracket to chassis bolts

. . . . ...

123

Drop arm to drag link castle nut

. . . . . . . . . . ...

81

Steering damper to drag link nut

. . . . . . . . . . ..

50

Drop arm to steering box nut

. . . . . . . . . . . ...

176

Radius arm to axle nuts

. . . . . . . . . . . . . ...

176

Steering box to chassis nuts

. . . . . . . . . . . .

81

Track rod clamp bolt nuts

. . . . . . . . . . . . . .

14

Drag link clamp bolt nuts

. . . . . . . . . . . . . ..

14

Steering wheel retaining nut

. . . . . . . . . . . .

30

Road wheel nuts

. . . . . . . . . . . . . . . . ..

108

Ball joint nuts

. . . . . . . . . . . . . . . . . .

41

Radius arms to chassis nuts

. . . . . . . . . . . .

176

Collapsible coupling nuts

. . . . . . . . . . . . . .

25

4

REISSUED:

FEB

1993

TORQUE WRENCH SETTINGS

POWER ASSISTED STEERING

Nm

Mounting bracket to front cover

. . . . . . . . . . ...

25

Mounting plate

to

mounting bracket

. . . . . . . . . .

25

Pulley to P A S pump

. . . . . . . . . . . . . . ...

9

P.A.S pump

to

mounting bracket

. . . . . . . . . . .

25

P.A.S box

16

mm thread

. . . . . . . . . . . . . ..

20

P.A.S pump union

. . . . . . . . . . . . . . . .

20

Mounting bracket

to

cylinder block

. . . . . . . . . ...

25

P.A.S box 14 mm thread

. . . . . . . . . . . . . ..

15

P.A.S pump Jubilee clips

. . . . . . . . . . . . . .

3

Brake caliper to swivel housing

. . . . . . . . . . .

100

Servo. primary port

. . . . . . . . . . . . . . . ..

13

Servo. secondary port

. . . . . . . . . . . . . . ..

13

Jump hose

-

female

. . . . . . . . . . . . . . . .

15

Wheel cylinders to back plate

. . . . . . . . . . . ..

11

'G' valve

. . . . . . . . . . . . . . . . . . . ...

10

'G' valve to bracket

. . . . . . . . . . . . . . . ..

13

Master cylinder

to

servo nuts

. . . . . . . . . . . ...

14

Servo to bulkhead nuts

. . . . . . . . . . . . . .

14

BRAKES

Brake disc to hub

. . . . . . . . . . . . . . . . .

72

Brake pipe connections to:

ELECTRICAL EQUIPMENT

Alternator:

Shaft nut

. . . . . . . . . . . . . . . . . ...

60

Through bolts

. . . . . . . . . . . . . . . .

5

Rectifier bolts

. . . . . . . . . . . . . . . .

3,5

Starter motor to engine bolts

. . . . . . . . . . . .

44

Starter motor:

Through bolts

. . . . . . . . . . . . . . . .

10,8

Solenoid fixing stud nut

. . . . . . . . . . . . .

6

Solenoid upper terminal nut

. . . . . . . . . . ..

4

Reverse light switch

. . . . . . . . . . . . . . . .

24

Lucas

35

DM8 Electronic ignition distributor

Pick up bearing plate support pillars

. . . . . . . . .

1,2

Pick up barrel nuts

. . . . . . . . . . . . . . . ...

1,2

AIR

CONDITIONING

Adaptor plate

to front cover

. . . . . . . . . . . . ..

45

Compressor mounting bracket

to

adaptor plate

. . . . ...

45

Compressor to mounting bracket

. . . . . . . . . . .

45

Adjusting link to mounting bracket & compressor

. . . .

45

Belt damper

to front cover plate

. . . . . . . . . . ...

36

Pulley to Torsional Vibration damper

. . . . . . . . ...

25

Mounting plates

to

compressor

. . . . . . . . . . .

25

5

REISSUED: FEB 1993

GENERAL FITTING INSTRUCTIONS

PRECAUTIONS AGAINST DAMAGE

PREPARATION

1.

Always fit covers to protect wings before

1.

Before removing a component, clean

it

and

its

commencing work in engine compartment.

surrounding areas as thoroughly as possible.

2.

Cover seats and carpets, wear clean overalls

2.

Blank

off

any

openings

exposed

by

and wash hands or wear gloves before

component removal, using greaseproof paper

working inside car.

and masking tape.

3.

Avoid spilling hydraulic fluid or battery acid on

3.

Immediately seal fuel, oil or hydraulic lines

paint work. Wash

off with water immediately

if

when separated, using plastic caps or plugs,

this occurs. Use Polythene sheets in boot to

to

prevent

loss of fluid and entry of dirt.

protect carpets.

4.

Close open ends of oilways, exposed by

4.

Always use a recommended Service

Tool, or

component removal, with tapered hardwood

a satisfactory equivalent, where specified.

plugs or readily visible plastic plugs.

5. Protect

temporarily

exposed screw threads by

5.

Immediately a component is removed, place

it

replacing nuts or fitting plastic caps.

in a suitable container; use a separate

container for each component and its

SAFETY PRECAUTIONS

-

(See also SECTION

01

associated parts.

-

Poisonous Substances)

6.

Before dismantling a component, clean

it

thoroughly with a recommended cleaning

1.

Whenever possible use a ramp or pit when

agent; check that agent is' suitable for all

working beneath vehicle, in preference

to

materials of component.

jacking. Chock wheels as well as applying

7 .

Clean bench and provide marking materials,

hand brake.

labels, containers and locking wire before

2. Never rely on a jack alone to support vehicle.

Use axle stands or blocks carefully placed at

jacking points

to

provide rigid location.

3.

Ensure that a suitable form

of

fire extinguisher

is conveniently located.

1.

Observe

scrupulous

cleanliness

when

4.

Check that any lifting equipment used has

dismantling components, particularly when

adequate capacity and is

fully serviceable.

brake, fuel or hydraulic system parts are being

5. Inspect power leads of any mains electrical

worked on. A particle

of dirt or a cloth

equipment for damage and check that

it

is

fragment

could

cause

a

dangerous

properly earthed.

6.

Disconnect earth (grounded) terminal of

2.

Blow out ail tapped holes, crevices, oilways

vehicle battery.

and fluid passages with an air line. Ensure

7 .

Do not disconnect

any

pipes in air

that any O-rings used for sealing are correctly

conditioning refrigeration system, if fitted,

replaced or renewed,

if

disturbed.

unless trained and instructed

to

do

so.

A

3.

Mark mating parts to ensure that they are

refrigerant is used which can cause blindness

replaced as dismantled. Whenever possible

if allowed to contact eyes.

use marking ink, which avoids possibilities

of

8.

Ensure that adequate ventilation

is

provided

distortion or initiation of cracks, liable

if

centre

when volatile degreasing agents are being

punch

or scriber are used.

used.

4.

Wire together mating parts where necessary
to prevent accidental interchange (e.g. roller

WARNING: Fume extraction equipment

bearing components).

must

be in operation when trachloride,

5. Wire labels on to all parts which are to be

methylene

chloride,

chloroform

or

renewed, and to parts requiring further

perchlorethylene are

used

for cleaning

inspection

before

being

passed

for

purposes

.

reassembly; place these parts in separate
containers from those containing parts for

9.

Do not apply heat in an attempt to free stiff

rebuild.

nuts

or

fittings; as well as causing damage to

6.

Do not discard a part due for renewal until

protective coatings, there is a risk of damage

after comparing it with a new part, to ensure

to electronic equipment and brake lines from

that its correct replacement

has

been

stray heat.

obtained.

10.

Do

not

leave

tools,

equipment, spilt oil etc.,

around or

on work area.

11.

Wear protective overalls and use barrier
creams when necessary.

dismantling a component.

DISMANTLING

malfunction

if

trapped in these systems.

REISSUED:

FEB

1993

1

GENERAL

FlTTlNG

INSTRUCTIONS

INSPECTION - GENERAL

it

could be established that damage was

1.

Never inspect a component for wear or

9.

When fitting bearing to shaft, apply force only

dimensional check unless

it

is absolutely

to inner ring of bearing, and only to outer ring

clean; a slight smear of grease can conceal
an incipient failure.

2.

When a component is to be checked
dimensionally against figures quoted for it, use
correct

equipment

(surface

plates,

micrometers, dial gauges, etc.) in serviceable

condition. Makeshift checking equipment can

be dangerous.

3.

Reject a component

if

its dimensions are

outside limits quoted, or

if

damage is

apparent. A part may, however, be refitted if

4. Use plasti-guage 12 Type PG-1 for checking

bearing surface clearances; directions for its

confined to

it

only.

when fitting into housing.

its critical dimesnion is exactly limit size, and

10.

In the case of grease-lubricated bearings (e.g.

hub bearings) fill space between bearing and
outer seal with recommended grade of grease
before fitting seal.

use, and a scale giving bearing clearances in

11.

Always

mark components of

separable

0,0025

mm steps are provided with it.

bearings (e.g. taper roller bearings)

in

dismantling, to ensure Correct reassembly.

Never

fit

new rollers in a used cup.

BALL AND ROLLER BEARINGS

NEVER

REPLACE

A BALL OR ROLLER BEARING

O

I

L SEALS

WITHOUT

FIRST ENSURING THAT

IS IN

A FULLY

SERVICABLE CONDITION

1.

Always fit new oil seals when rebuilding an
assembly. It is not physically possible to

1.

Remove all traces of lubricant from bearing

replace a seal exactly when

it

has bedded

under inspection by washing

in petrol or a

down.

suitable

degreaser;

maintain

absolute

2.

Carefully examine seal before fitting to ensure

cleanliness throughout operations.

that it is clean and undamaged.

2. Inspect visually for markings of any form on

3.

Smear sealing lips with clean grease; pack

rolling elements, raceways, outer surface of

dust excluder seals

with

grease, and heavily

outer rings or inner surface of inner rings.

grease duplex seals in cavity between sealing

Reject any bearings found to be marked,

lips.

since any marking in these areas indicates

4.

Ensure that seal spring, if provided, is

onset of wear.

correctly fitted.

.

Holding inner race between finger and thumb

5.

Place lip of seal towards fluid to be sealed

of one hand, spin outer race

and

check that

it

and slide into position on shaft, using fitting

revolves absolutely smoothly, Repeat, holding

sleeve when possible to protect sealing lip

outer race and spinning inner race.

from damage by sharp corners, threads or

4.

Rotate outer ring gently with a reciprocating

splines, If fitting sleeve is not available, use

motion, while holding inner ring; feel for any

plastic tube

or

adhesive tape to prevent

check or obstruction to rotation, and reject

damage to sealing lip.

bearing if action is not perfectly smooth.

5.

Lubricate bearing generously with lubricant
appropriate to installation.

6.

Inspect shaft and bearing housing for
discolouration or other marking suggesting

i

that movement has taken place between

bearing and seatings. (This is particularly to

be

expected if related markings were found in

operation

2.)

If markings are found, use

'Loctite' in installation of replacement bearing.

7.

Ensure that shaft and housing are clean and

free from burrs before fitting bearing.

8.

I f one bearing of a pair shows an imperfection

it

is

generally advisable to renew both

bearings: an exception could be made

if

the

faulty bearing had covered a low mileage, and

2

REISSUED: FEB 1993

is otherwise satisfactory.