Land Rover Defender 90 110 Workshop Book 1 Rover
Have a look at the manual Land Rover Defender 90 110 Workshop Book 1 Rover online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 364 Land Rover manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
Lubrication nipples (hubs, ball joints, etc.) ~~. ., - ßP Castrol Duckhams Esso Mobil- Fina Shell Marfak Energrease LM Grease LU 10 Multi- grease MP Marson Ketinax A All purpose L2 pumosc HTL 2 Grease Cooling system Anti -freeze Universal Anti-freeze See under Anti-freeze section 09. RECOMMENDED LUBRICANTS AND FLUIDS Service instructions for temperate climates - ambient temperature range -10°C to 35°C COMPONENTS BP I CASTROL PETROFINA I SHELL I TEXACÖ~ DUCKHAiMS Duckhams 15W/S0 Hypergrade Motor Oil ESSO MOBIL Engine V8 Carburetter Dashpots Fina Shell Super Havoline Supergradc Motor Oil Motor Oil Motor Oil 15W/40 or 15W/40 or 10W/40 or IOW140 Eurotex HD 15W/40 10WBO (15W/50) or Superlube Super (15W/40) 10W/40 or Kally Formula 15W/50 Nova llOW/40 1 Duckhams 15W/SO Hypergrade Motor Oil Esso 1 Mobil 1 Fina 1 Shell Super Superlube Super Supergrade Motor Oil (15W/40) 10W/40or MotorOil 15W/40 or Mobil 1 Rally 1OW/40 or low140 Formula 15W140 Havoline Motor Oil i15W/40 1 Engine 4-cyl. pctrol 15W/40 Shell Super Supergrade Motor Oil 1 OW/40 or Super 15W/40 RimulaX plus 1 15Wi40 or Engine 4-cyl. diesel Duckhams 15w/50 Hypergrade Motor Oil or Duckhams Fleetol Multi-V 20Wi50 or Duckhams Fleet Master 15w/40 Duckhams Q-Matic or Mobil 1 Eurotex Rally Motor Oil Formula town0 Tvoe G LT77-five- speed gearbox LT95 - four- speedgearbox including transfer box Front differential Rear differential jwivel pin iousings and -R30R & LT23OT rransfer box 2T85 -five- ,peed gearbox - /8 cylinder Duckhams 15W/50 Esso Mobil Fina Shell Super Havoline Superlube Super Supergrade Motor Oil Motor Oil (15W140) IOW140 Motor Oil 15W/40 or 1SW140 or 10W/40 or 1 OW/40 Eurotex HD 15w/40 IOW/30 Esso Mobil Fina Shell Texaco Hypergrade Motor Oil Duckhams Hypoid 90 Gear Oil Mobilube Pontonic MP Multigear GX 1 HDW ISAEXOW/90 I Lubricant 35w/90 EP 85W190 I 3ils lisled on lines marked (*) may transfer box. so be used in LTZ! 3P Visco !Ooo 15W/40) or 3P Visco (ova 10W/40) mergrease -2 %P Gear Oil #AB 90EP !P Castrol GTX (15W/50) Duckhams Esso Mobil Fina Shell Hypergrade Superlube Super Supergrade Super Multigrade 15W/50 15W/40 10w/40 Motor Oil 10W/40 or 15w/40 15W/40 or 10W/40 Havoline Motor Oil 15 W/40 or Eurotex HD 10W/30 Marfak All purposc Grease Texaco Multigear Lubricant EP 85W/90 Texamatic Fluid 9226 Duckhams Esso Mobil- LB 10 I Multi- Castrol LM Grease :rant and rear lteering box Manual) I purposc I- I I Grease I I I Duckhams Esso Mobil Fina Shell Hypoid 90 Gear Oil Mobilube Pontonic MP 1 s5w/90 GX 1 HD9U /SAESOW/9O 1%;; Castrol HYPOY SAE 90EP Castrol TO Dexron IID Duckhams 1 Y;; 1 Mobil 1 Fina Shell Fleetmatic CD ATF 220 D Dexron IID 1 ATF or Dexron IID Dexron IID ower steering uid reservoir s applicable DX 2D Esso Mobil Fina Shell Super Superlube Super Supergrade Motor Oil (15W/40) 15W/40 Motor Oil 15W/40or i 10W/40 or 1OW/40 15W/40or 1 OW/40 Duckhams D-Matic Duckhams I5W/50 Hypergrade Motor Oil iir cleaner -cyl. petrol UP Visco (15W/40)or ßP Visco (IOW130) BP Visco (15W/40) or I BP Visco Castrol GTX (15W/5!)or Castrolite Havoline Motor Oil low130 or Eurotex HD lowno Havoline Motor Oil 15 W/40 or 10W/30 or Eurotex HD 1OW/30 ( 10 W/40) ir cleaner -cyl. diesel Castrol GTX (15W150) or Castrolitc (I Uw140) 15W/40 or Owl40 rake and clutch Universal Bra ! Ihid or other brake fluids having a minimum boiling point of 260°C (500°F) and comnlvine with FMVSS 116 DOT 3 reservoirs I Top link .. 1
COMPONENTS I BP retention clips Door lock striker Windscreen washers H All Seasons Screen Washer Fluid ~~ Door locks (anti-burst) Inertia reels ~ ~~ ~ - ~~~~ DO NOT LUBRICATE. These components are life lubricated at the manufacturing stage API service levcls SE or SF or SEICC or SFICC or SEICD or SFKD or the CCMC requirements API service levels CC or CD or SEICC or SE/CD or SFICC or SFICC or the CCMC requirements 09 I RECOMMENDED LUBRICANTS, FLUIDSAND CAPACITIES RECOMMENDED LUBRICANTS AND FLUIDS SERVICE INSTRUCTIONS ALL MARKETS ll CASTROL DUCKHAMS I ESSO SPEC. REF. TEXACO BRANDS Marfak NGLI -2 ;; Multi- MOBIL ~ Windscreen hinges Ventilator hinges Ventilator control Seat slides. Hood BP Energrcase LM Grease LB 10 Multi- L2 purpose Grease 1 Castrol 1 Duckhams 1 Esso Mobil Mobil- Shell Marson Retinax HTL2 grease MP based Bonnet ointle I Graohite Lock Grease Tvoe B Battery lugs Earthing surfaces Where paint has been removed Petroleum jelly. NOTE: Do not use Silicone Grease ~- METHYLCHLORIDE REFRIGERANTS MUST NOT BE USED Air Conditioning System Refrigerant Compressor Oil C . ~ -- Use only refrigerant 12. This includes Freon 12 and Arcton 12 Shell Clavus 68 BP Energol LPT 68 Sunisco 4GS Texaco Capella E Wax Free 68 RECOMMENDED LUBRICANTS AND FLUIDS SERVICE INSTRUCTIONS FOR AMBIENT CONDITIONS OUTSIDE TEMPERATE CLIMATE LIMITS OR FOR MARKETS WHERE THE PRODUCTS LISTED ARE NOT AVAILABLE COMPONENTS SERVICE CLASSIFICATION WORLDWIDE AiMßIENT TEMPERATURE C I PERFORMANCE LEVEL SAE VISCOSITY -30 -20 -10 0 10 20 30 40 50 1 Engine Carburetter dashpotr Oil can Oils Oil bath air cleaners Petrol 1 Diesel sw120 swi30 5 Wl40 10w130 10w140 low150 15w140 1sw150 20W/40 20Wi50 oils must meet ßL I Oils must meet BI. Cars spec. Cars spec. BLS.22.OL.02 BLS.22.OL.02 an( or MIL-L-461S2A or Power steering reservoir ATF M2C 33 For G ~~~ Front and rear Axle differential Swivel pin housing LT230 transfer bo, Steering box API GL4 or MIL-Ir2105 90 EI 80W EP LI77 eearbox ATF M2C 33 F or G Ll%iearbox including :ransfer box Oils must mcet BL Cars spec. BLS.22.OL.02 or API service levels SE or SF or SE/CC or SEICD or SF/CC or SFICD or the CCMC 10W130 IOW140 IOWlS0 IOW140 IOW150 1sw140 15w150 2ow140 20w150 requirements LT85 gearbox - V8 cylinder Oils must meet ßL 1ow130 10w140 1ow15o Cars spec. BLS.22.OL.02 or API servicc levels SE or SF or SEICC ?r SE!C_n or SE!CC 3r SWCD or thc XMC requirements Brake fluid must have a minimum boiling point of 260°C (500°F) and comply with FMVSS 116 DOT 3 VLGI -2 multipurpose lithium based grease 3rake and clutch eservoirs xbrication nipples hubs, ball joints, etc) 2
RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES 109 I - . !.. :.. .!, .I I, .. .. I. ....... I. . . _. .... .. .. ..... .. I .., .... :. : ....... . (. . ....... ., ..,? , . .... ..... ANTI-FREEZE Use only UNIVERSAL Anti-freeze or an Ethylene Glycol based anti-freeze, containing no methanol, with non-Phosphate corrosion inhibitors suitable for use in cast iron and aluminium alloy engines to ensure protection of the cooling system against frost and corrosion. Percentage Engine Mixture Concentration Protection One part anti-freeze two parts water 33% Down to -20°C One part anti -freeze one part water 50% Below -20°C to One part anti -freeze one part water 50% Down to -36°C -36°C i 4-cyl. Engines (cast iron) V8 Engine (aluminium) IMPORTANT: Coolant solution must not fall below proportions of one part anti-freeze to three parts water, i.e. min. 25 anti-freeze in coolant, otherwise damage to engine is liable to occur. CORROSION INHIBITOR When anti-freeze is not required the cooling system must be flushed out with clean water and filled with a solution of ONE PART MARSTONS SQ 36 inhibitor to NINE parts water to provide a 10 mixture concentration. CAPACITIES The following capacity figures are approximate and are provided as a guide only. All oil levels must be set using the dipstick or level plugs as applicable. Component Litres Imperial unit Engine sump oil, 4-cylinder.. ............................................. Extra when refilling after fitting new filter, 4-cylinder.. ............ Air cleaner oil, 4-cylinder ................................................. Extra when refilling after fitting new filter, V8 cylinder.. .......... Main gearbox oil, five-speed ............................................. Engine sump oil, V8 cylinder ............................................. Transfer box oil, LT230R five-speed main gearbox.. ............... LT85 five-speed gearbox .................................................. LT230T transfer gearbox .................................................. Main gearbox oil, four-speed ............................................. Transfer gearbox oil, four-speed main gearbox ...................... Front differential ............................................................ Rear differential: Salisbury 8HA ........................................ Swivel pin housing oil (each) ............................................. Fuel tank, rear ............................................................... Fuel tank, side (except Station wagon) ................................. Fuel tank, side (Station wagon only) .................................. Cooling system, 4-cylinder petrol models (standard) ............... Cooling system, 4-cylinder diesel models and heavy duty petrol models .............................................................. Cooling system, V8 cylinder modcls.. .................................. Steering box manual.. ...................................................... Power steering box and reservoir fluid ................................. 6,OO 0,85 0,85 5,lO 0,56 2,20 2,80 3,OO 2,80 2,60 3,16 1,70 2,30 0,35 79,50 68,20 45,50 10,30 11 ,oo 12,80 O,43 2,90 11 .OO pints 1.50 pints 1.50 pints 9.00 pints 1.00 pint 3.90 pints 4.90 pints 5.25 pints 4.9 pints 4.70 pints 5.50 pints 3.00 pints 4.00 pints 0.60 pint 17.50 gallons 15.00 gallons 10.00 gallons 18.00 pints 19.00 pints 22.50 pints 5.0 pints 0.75 pints 3
MAINTENANCE I 10 I MAINTENANCE SCHEDULES Revised Maintenance Schedules are introduced with the commencement of the Land Rover Ninety V8 model range. The new schedules also apply to four -cylinder, petrol and diesel models, and feature a reduced 10.000 km (6,000 miles) service. The new schedules supersede previous issues. Efficient maintenance is one of the biggest factors in ensuring continuing reliability and efficiency. For this reason the following detailed schedules are included so that at the appropriate intervals owners and operators may know what is required. The Maintenance Schedules are based upon intervals of 10.000 km (6,000 miles) or 6 months unless otherwise stated. Note: The 10.000 km service must be repeated every 10.000 km (6,000 miles) or six months, whichever is first. The 20.000 km service must be repeated every 20.000 km (12.000 miles) or 12 months, whichever is first, with additional maintenance at the intervals specified in the schedule. Every Every 1O.OOo km 20.000 km (6.0 miles) (12.000 miles) or6months or 12months 1 2 3 Check operation of horns 4 5 6 7 8 0 Check rear view mirror(s) for security, 9 0 Check condition and security of seats, seat 0 Check operation of all lamps a Check operation of warning indicators 0 Check operation of windscreen and rear 0 Check condition of wiper blades 0 Check security and operation of handbrake belt mountings, seat belts and buckles wipers and washers cracks and crazing tailgate locks 10 0 Check operation of window controls 11 0 n Lubricate all locks (not steering lock) hinges and door - check mechanisms 12 0 Lubricate accelerator control linkage and pedal pivot 13 14 0 ChecWadjust headlamp alignment 15 0 Check front wheel alignment 16 17 0 Remove battery connections, clean and 18 0 Removeroadwheels 0 Check operation of all doors, bonnet and 0 ChecWadjust tyre pressures including spare a 0 ChecWtop-up battery electrolyte grease (refit) . 19 20 21 22 23 24 25 26 27 28 29 U U 0 0 0 0 0 0 n n 0 0 Check tyres comply with Manufacturers specification Check tyres visually for cuts, lumps, bulges, uneven wear and tread depth Remove road wheel brake drums, wash out dust, inspect shoes for wear and drums for condition Inspect wheel cylinders for fluid leaks Inspect brake pads for wear, calipers for leaks, and discs for condition Refit road wheel brake drums Adjust road wheel brakes Adjust handbrake if required Refit road wheels to original position Renew engine oil Renew engine oil filter Every 4O.wO km 30 24.000ml Renew gearbox oil Every Every 1O.ooO km 20.000 km (6.000 miles) (12,000 miles) or6months or 12month; -- 31 U U Every 40.000 km 32 24.000 ml 33 a 0 35 0 0 37 0 0 39 0 0 Every 40.003 km 34 24.lXXl ml Every 4O.lXK) km 36 24.WOml Every 40.000 km 38 24,~ml 40 a 0 42 0 Every 4O.OlKl km 41 24.000 ml 43 0 0 44 D 45 U 46 U 47 0 0 48 U 49 0 50 U 51 U - U Every 80.0W km 52 53 48,000 ml 54 U 55 I 56 0 58 U Every40.000 km 59 24.000ml ChecWtop-up gearbox oil Renew transfer box oil CheeWtop-up transfer box oil Renew front axle oil ChecWtop -up front axlc oil Renew swivel pin housing oil ChecWtop -up swivel pin housing oil Renew rear axle oil ChecWtop -up rear axle oil Lubricate rear suspension upper link ball joint Lubricate propeller shaft sealed sliding joints Lubricate propeller shaft universal joints Lubricate handbrake mechanical linkage Check visually brakc, fuel, clutch pipeshnions for chafing, leaks and corrosion Check exhaust system for leakage and security Check for oil leaks from engine and transmission Check for oil/fluid leaks from stcering and suspension systems Check axlc breather pipes, ensure they arc not blocked, pinched or split Check security and condition of suspension fixings Check condition and security of steering unit, joints and gaiters Check tightness of propeller shaft coupling bolts Clean fuel sedimenter (Diesel only) Clean electric fuel pump filter Renew fuel filter element (Petrol) Drain flywheel housing if drain plug is fitted for wading (refit) Clean camshaft drive belt housing filter (Diesel) Check c~ndltien ef heater p!~g wiring fs: fraying, chafing and deterioration (diesel only) Remove heater plugs, clean, test and refit (diesel only) Remove diesel injectors, clean, test and refit 1
El MAINTENANCE Every Every 1O.ooO km 20.000 km (6.000 miles) (12.000 miles) or 6 months or I2 months 0 Renew fuel filter element (Diesel) - 60 Every Every IO.o(K) km 2O.ooO km (6.000 miles) ~12.ooO miles) or 6 months br 12 months 61 62 0 Cleardadjust spark plugs 63 0 Renew spark plugs 64 0 Renew air cleaner elements 65 66 24,001) ml Renew engine breather filter (V8) 67 0 Clean engine breather filter (all models except V8) Checkladjust valve clearance (all models except V8) 0 Check air cleaner dump valve, clean or renew EveryJ0.000 km 0 Renew engine flame trap(s) (V8) 68 Every60.000 km 69 36.000ml Renew brake Servo filter 70 71 72 73 74 Top -up carburetter piston dampers 75 0 ChecWtop-up cooling system 76 0 0 Checktop-up fluid in power steering reservoir 77 78 0 ChecWadjust steering box 79 0 0 Check/top-up clutch fluid reservoir 80 0 0 Checktop-up brake fluid reservoir 81 0 0 Check/top-up windscreen and rear washer reservoir 82 0 Check cooling and heater system for leaks, hoscs for security and condition 83 0 0 Check power steering system for leaks, hydraulic pipes and unions for chafing and corrosion Check condition of driving belts - adjust if required (not camshaft drive belt - diesel) 0 Check ignition wiring and HT leads for fraying, chafing and deterioration 0 Clean distributor cap, check for cracks and tracking Check brake Servo hose for security and condition hoses/pipes for security and condition n Check air injection/pulsair system 0 Check operation of pulsair check valves hoses for security and condition 0 0 Check crankcase breathing system for leaks, 0 Checktop-up steering box (manual steering) 84 85 86 0 0 87 88 24.lXM ml Renew distributor points (not V8) 89 Lubricate distributor (not V8) 90 91 0 Check dwell angle -adjust as necessary 92 0 0 ChecWadjust ignition timing 0 Clean/adjust distributor points (not V8) Every 41.000 km Check voltage drop between coil CB and earth (not V8) Note: It is important that the ignition timing, dwell angle and carburetter adjustments are set in accordance with the vehicle engine spenfcation and fuel Octane rating. Refer to the relevant repair operation manual for details 93 a Check throttle operation 94 0 0 ChecWadjust engine idle speed, and carburetter mixture settings with engine at normal running temperature Check operation of air intake temperature control system (V8) Carry out road or roller test - Check: 95 0 96 0 0 For excessive engine noise 97 0 0 Clutch for slippindjudder/spinning 98 0 0 Gear selectiodnoise - high and low range 99 0 0 Steering for noise/abnormal effort required 100 0 0 All instruments, pressure, fuel and 101 102 0 0 Heatedrearscreen 103 104 0 0 Foot brake, on emergency stop, pulling to one side, binding, pedal effort 105 0 0 Handbrakeefficiency 106 0 0 Operation of inertia seat belts 107 a Roadwheel balance 108 0 0 Transmission for vibrations 109 0 0 For body noises (squeaks and rattles) 110 0 0 Fuel governor cut-off point 111 0 0 For excessive exhaust smoke 112 0 0 Engineidlespecd 113 0 Endorse service rccord 114 0 a Report any additional work required temperature gauges, warning indicators 0 0 Heater and air conditioning systems 0 0 Shock absorbers (irregularities in ride) c3 a.: -.:/ WARNING: Two-wheel roller tests must be restricted to 5 kdh (3 m.p.h.) because the Land Rover One Ten and Ninety is is constant four-wheel drive. At 100.000 km (60?000 mile) intervals it is imperative that the camshaft drive belt be renewed, failure to do so could result in serious engine damage. RECOMMENDATIONS At 30.000 km (18,000 mile) intervals or every 18 months, whichevcr is the sooner, the hydraulic brake fluid should be completely renewed. At 40.000 km (24,000 mile) intervals remove the Pulsair injection manifold and connecting pipes, ensure that the internal bores and the cylinder head drillings are clean and free from obstructions, clean as necessary and refit. (Emission control V8 petrol engines) At 60.000 km (36,000 mile) intervals or every 3 years, whichever is the sooncr, all hydraulic brake fluid, seals and flexible hoses should be renewed. all working surfaces of the master cylinder, wheel cylinders and caliper cy!inders should be examined and renewed where necessary. At 60.000 km (36,000 mile) intervals remove all suspension dampers, test for correct operation, refit or renew as necessary. Vehicles fitted with free wheeling front hubs The hubs require no routine maintenance. When the hub bearings are adjusted, or any time the vehicle has been used for wading, the moving parts of the free wheel hubs should be lightly smeared with Rocol 1000 grease or a similar molybdenum disulphide bearing grease. 2 &-? E. -.. I
MAINTENANCE Gi ,;:,,.::.>, T LUBRICATION a;,-;;. :? . ., ... . . .. This first part of the maintenance section covers renewal of lubricating oils for the major units of the vehicle and other components that require lubrication, as detailed in the ‘Maintenance schedules’. Refer to the ‘General specification data’ for capacities and recommended lubricants. Vehicles operating under severe conditions of dust, sand, mud and water should have the oils changed and lubrication carried out at more frequent intervals than that recommended in the maintenance schedules. Draining of used oil should take place after a run when the oil is warm. Always clean the drain and filler-level plugs before removing. In the interests of safety disconnect the vehicle battery to prevent the engine being started and the vehicle moved inadvertently, while oil changing is taking place. Allow as much time as possible for the oil to drain completely except where blown sand or dirt can enter the drain holes. In these conditions clean and refit the drain plugs immediately the main bulk of oil has drained. Where possible, always refill with oil of the make and specification recommended in the lubrication charts and from sealed containers. T. .
1x1 MAINTENANCE Renew oil filter - 2.25 petrol and diesel engine RENEW MAIN AND TRANSFER GEARBOX OILS DRAIN AND REFILL LT77mm MAIN GEARBOX 4 -cylinder engines @ 8. Place oil tray under engine. 9. Unscrew filter retaining bolt. 10. Remove the container. 11. Remove the element. 12. Discard the used filter element and large rubber washer. 13. Wash the container in kerosene. 14. Place the new filter element in the container and reassemble the unit, using the new large rubber washer supplied with the element. 15. Ensure that all the sealing washers are in position and intact, and that the container is correctly located in the adaptor. 16. Tighten the filter retaining bolt to the correct torque. Do not overtighten. Sl Refill sump with oil -all models 1. Drive the vehicle to level ground and place a suitable container under the gearbox to catch the old oil. 2. Remove the gearbox and extension case drain plugs and allow the oil to drain completely. Wash the extension case filter in kerosene and refit the plugs using new washers, if necessary, and tighten to the correct torque. ST 919M U 3. Remove the oil filler-level plug and inject the approximate quantity of new oil of the correct make and grade until it begins to run out of the filler -level hole. Fit the plug and tighten to the coirect torque. Since the plug has a tapered thread it must not be overtightened. Wipe away any surplus oil. 17. Check that the drain plug is tight. 18. Clean the outside of the oil filler cap, remove it from the rocker cover and clean the inside. 19. Pour in the correct quantity of new oil of the correct grade from a sealed container to the high mark on the dipstick and firmly replace the filler cap. 20. Run the engine and check for leaks from the filter. Stop the engine, allow the oil to run back into the sump for a few minutes, then check the oil level again and top up if necessary. 4
MAINTENANCE 110 I DRAIN AND RENEW 230R AND 230T TRANSFER GEARBOX (4-cylinder engine) 1. Drive the vehicle to level ground and place a container under the gearbox to catch the old oil. 2. Remove the drain plug and allow the oil to drain. Fit the plug using a new washer, if necessary, and tighten to the correct torque. 3. Remove the filler -level plug and inject the approximate quantity of the recommended oil until it begins to run from the plug hole. Fit the level plug and tighten only to the correct torque, do not overtighten, wipe away any surplus oil. ST1070M DRAIN AND RENEW LT95 MAIN GEARBOX (V8 engines) 1. Drive the vehicle to level ground and place a container under the gearbox to catch the old oil. 2. Remove the drain plug, washer and filter from the bottom of the gearbox casing and allow the oil to drain completely. 3. Wash the filter in petrol, allow to dry and fit to the casing. Using a new washer, if necessary, fit the plug and tighten to the correct torque. 4. Remove the oil filler-level plug from the side of the gearbox and inject the approximate quantity of the correct oil until it begins to run from the filler -level hole. Clean and refit the plug using a new washer and tighten to the correct torque. Wipe away any surplus oil. DRAIN AND RENEW LT95 TRANSFER GEARBOX OIL 1. Drive vehicle to level ground and place a container beneath the gearbox to catch the old oil. 2. Remove the drain plug and allow time for the oil to drain completely. 3. Clean and refit the drain plug using a new washer, if necessary and tighten to the correct torque. 4. Remove the oil filler-level plug and inject the approximate quantity of a recommended oil until it begins to run from the hole. Clean and fit the plug and tighten to the correct torque. Do not overtighten. Wipe away any surplus oil. RENEW FRONT AND REAR AXLE OIL 1. Drive the vehicle to level ground and place a container under the axle to be drained. 2. Using a spanner with a 13 mm (0.5 in) square drive remove the drain plug and allow the oil to drain completely. Clean and refit the drain plug. 3. Remove the oil filler-level plug and inject new oil of a recommended make and grade until it begins to run from the hole. Clean and fit the filler -level plug and wipe away any surplus oil. NOTE: Whilst the illustration shows a ‘90’ model front differential, the procedure is the same for all axles. 5
El MAINTENANCE RENEW SWIVEL PIN HOUSING OIL 1. Drive the vehicle to level ground and place a container under each swivel housing to catch the used oil. 2. Remove the drain plug and allow the oil to drain completely and clean and refit the plugs. 3. Remove the oil filler-level plug and inject the recommended make and grade of oil until oil begins to run from the level hole. Clean and fit the level plugs and wipe away any surplus oil. LUBRICATE PROPELLER SHAFTS 1. Clean all the grease nipples on the front and rear propshaft universal joints, and sliding portion of the rear shaft. 2. Charge a low pressure hand grease gun with grease of a recommended make and grade and apply to the grease nipples. 3. Remove the screwed plug from the front shaft and fit a suitable grease nipple. 4. Disconnect one end of the front propeller shaft and compress the sliding portion whilst applying grease. It is necessary to compress the shaft to prevent over filling with grease. It should be noted that this sliding portion must only be lubricated at 40.000 km (24,000 mile) intervals. 5. Reconncct the propeller shaft, remove the grease nipple and fit the screwed plug. TOP-UP MANUAL STEERING BOX 1. Remove the oil filler plug and observe the oil level which should be 25 mm (1.0 in) below the top of the filler hole. 2. If necessary top-up to the correct level with a recommended oil. Clean and refit the plug and wipe away any surplus oil. ST 925M // RENEW AIR CLEANER OIL - 2.25 litre engines (early models) 1. Slacken wing nut and release the clamping strap securing the complete air cleaner. 2. Disconnect the outlet elbow from the intake pipe and remove the clcaner from thc vehicle. 3. Remove the oil bowl from the bottom of the cleaner by releasing the three securing clips. 4. Clean all dirty oil and sludge from the bowl and refill with fresh engine oil to the level indicated by a ring formed in the pressing; the capacity is approximately 0,85 litre (1.5 imperial pints). 5. Clean the spiral in the cleaner body by swilling the complete body in paraffin and shake off the ct 6. Remove and clean the air intake cap. 7. Clean the wire mesh filter. 8. Reassemble filter using a new scaling ring. 9. Refit the complete unit into the vehicle. surplus. -d 6
MAINTENANCE I 10 I L7Xp :. ..:? Diesel engine TOP -UP BRAKE VACUUM PUMP OIL - 2.25 litre TOP-UP CARBURETTER PISTON DAMPER - V8 only . .. . ..-I 1.1, 1. Slacken the drive belt, and the pump pivot bolts 1. Unscrew the cap on top of both suction chambers and withdraw the damper. 2. Move the pump to an upright position and 2. Top-up the reservoir with engine oil to within 12 mm (0.5 in) from the top of the hollow piston rod. Refit the damper and secure the cap. and nuts and slip the belt from the pulley. temporarily tighten the nuts and bolts to maintain this position. 3. Turn the pump pulley so that the indicating marks on the pulley hub and pump body line up. - . .. ,. . .. .. I, :, : .. . .~ ... .._ ,* .. . .. .. . 3 4. Remove the oil level plug at the rear of the pump and if necessary inject a recommended SAE 15W-50 oil up to the level of the hole. 5. Refit the level plug, and fit and tension the drive belt. ST 4 1008M /4 REAR SUSPENSION BALL JOINT 1. Apply a grease gun to the nipple using a recommended grease. RENEW LT85 MAIN GEARBOX OIL Drain and refill monthly when operating under severe wading conditions. To change the gcarbox oil proceed as follows: 1. Immediately after a run when the oil is warm, drain off the oil into a container by removing the drain plug and washer from the bottom of the gearbox casing. 2. Remove the oil filter. 3. Wash the filter in clean fuel; allow to dry and replace. 4. Clean and refit drain plug and washer and refill gearbox through the oil level/filler plug, with the correct grade of oil, to the bottom of the oil 1eveYfiller hole. For capacity see Data Section. 7