Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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10MAINTENANCE 8 MAINTENANCE CHECK/TOP UP BRAKE FLUID RESERVOIR WARNING: DO NOT drive the vehicle with the fluid level below MIN mark. Brake fluid will damage painted surfaces; clean up any spillage immediately and rinse with plenty of water. If brake fluid should come into contact with skin or eyes, rinse immediately with plenty of water. 1.Check the fluid level visually through transparent side of reservoir without removing cap. 2.If level is below MAX mark clean and remove reservoir cap. 3.Top up to MAX mark with recommended brake fluid See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids CHECK/TOP UP WASHER RESERVOIR Top up washer reservoir to within 25 mm (1.0 in) of filler neck. Use a screen washer solvent/anti-freeze solution to assist removing mud, flies, and road film and protect against freezing. LUBRICATE ACCELERATOR LINKAGES Lubricate accelerator cable at adjustment ferrule and linkage with injector pump and at pedal clevis pin.CHECK/ADJUST ENGINE IDLE SPEED Check/adjust low and high engine idle speed with engine at normal running temperature. See FUEL SYSTEM, Adjustment, low and high idle speed adjustment CHECK/ADJUST STEERING BOX Check steering box and pipes/hoses for fluid leaks. Check that there is no backlash in steering box when in straight ahead position. Adjust steering box if necessary. See STEERING, Adjustment, Power steering box VISUALLY CHECK INTERCOOLER/RADIATOR FOR EXTERNAL OBSTRUCTIONS Check intercooler/radiator for external obstructions. If necessary, apply air pressure to engine side of matrix to clear obstruction. If mud or dirt is evident, carefully use a hose to wash away obstruction. FLUSH DIESEL INTERCOOLER Remove 1.Remove intercooler matrix. See FUEL SYSTEM, Repair, Intercooler 2.Flush matrix with ICI GENKLENE proprietary cleaner, following manufacturers instructions. 3.Dry intercooler completely ensuring that no liquid remains in matrix. Refit 4.Refit intercooler matrix. See FUEL SYSTEM, Repair, Intercooler
MAINTENANCE 9 MAINTENANCE REV: 05/99 UNDER VEHICLE MAINTENANCE NOTE: A chassis undertray may be fitted on some vehicle derivatives to conform to legal requirements. When under chassis maintenance, or remove and refit procedures are required, it may be necessary to remove the undertray and/or integral access panels See CHASSIS AND BODY, Repair, Front undertray or See CHASSIS AND BODY, Repair, Rear undertray RENEW ENGINE OIL AND FILTER 1.Ensure vehicle is level. 2.Run engine to warm oil, switch off ignition. 3.Disconnect battery. 4.Place suitable drain tray under sump drain plug. 5.Remove drain plug from sump and allow oil to drain completely. 6.Fit new sealing washer, replace plug and tighten to 35 Nm (26 lbf/ft). 7.Place drain tray under oil filter. 8.Unscrew filter anti-clockwise, using a strap wrench if necessary. 9.Clean mating face of oil filter adaptor. 10.Coat rubber sealing washer of new filter with clean engine oil. 11.Screw filter on clockwise until sealing washer touches adaptor mating face, tighten a further half turn by hand only. DO NOT overtighten. 12.Clean and remove filler cap from rocker cover. 13.Pour in correct quantity and grade of new oil from a sealed container. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids 14.Check that oil level is between upper and lower marks on dipstick. DO NOT fill above upper mark. 15.Firmly replace filler cap. 16.Reconnect battery, run engine and check oil filter for leaks. 17.Stop engine, allow oil to run back into sump for a few minutes and check oil level again. Top up if necessary.
10MAINTENANCE 10 MAINTENANCEREV: 05/99 RENEW GEARBOX OIL 1.Ensure vehicle is level. 2.Place suitable tray under gearbox. 3.Disconnect battery. 4.Clean area around filler/level plugs. 5.Remove both plugs and allow oil to drain completely. WARNING: When draining gearbox, care should be taken to ensure that oil is not hot as personal scalding could result. 6.Refit drain plug and tighten to 30 Nm (22 lbf/ft). 7.Inject new oil into gearbox until it runs out of filler hole. Allow excess oil to drain and wipe clean. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids 8.Refit filler/level plug and tighten to30 Nm (22 lbf/ft). 9.Reconnect battery. RENEW TRANSFER GEARBOX OIL 1.Ensure vehicle is level. 2.Disconnect battery. 3.Clean area around filler/level and drain plugs. WARNING: When draining gearbox care should be taken to ensure that oil is not hot as personal scalding could result. 4.Place suitable tray under transfer gearbox. 5.Remove filler/level plug to vent gearbox and assist draining. 6.Remove drain plug and allow oil to drain. 7.Thoroughly clean drain plug threads and apply fresh Hylomar sealant. 8.Refit drain plug and tighten to 30 Nm (22lbf/ft). 9.Inject new oil of correct quantity and grade into gearbox until oil runs out from filler/level hole. Allow excess oil to drain and wipe clean. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids 10.Thoroughly clean filler/level plug and apply fresh Hylomar sealant. 11.Refit plug and tighten to 30 Nm (22 lbf/ft). 12.Reconnect battery. CHECK/TOP UP TRANSFER GEARBOX OIL 1.Ensure vehicle is level. 2.Disconnect battery. 3.Clean area around filler/level plug. 4.Remove plug, check oil level and top up if necessary with correct grade of oil, See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids until oil runs out from filler/level hole. Allow excess oil to drain and wipe clean. 5.Thoroughly clean filler/level plug threads and apply fresh Hylomar sealant. 6.Refit plug and tighten to 30 Nm (22 lbf/ft). 7.Reconnect battery.
MAINTENANCE 11 MAINTENANCE REV: 05/99 RENEW FRONT AND REAR AXLE OIL 1.Ensure vehicle is level and place suitable tray under axle to be drained. 2.Using 13mm square drive wrench, remove drain and filler/level plugs from axle and allow oil to drain completely. 3.Clean and refit drain plug. A- Front and rear axle, 90 models, front, 110/130 models.B- Rear axle, 110/130 models. 4.Inject new oil, See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids until it runs out from filler/level hole. Allow excess oil to drain and wipe clean. 5.Clean and refit filler/level plug. CHECK/TOP UP FRONT AND REAR AXLE 1.Ensure vehicle is level. 2.Using 13 mm square drive wrench, remove filler/level plug.3.If necessary inject new oil until oil runs out from filler/level hole. Allow excess oil to drain and wipe clean. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids 4.Clean and refit filler/level plug. RENEW SWIVEL PIN HOUSING OIL 1.Ensure vehicle is level and place suitable tray under swivel to be drained. 2.Remove drain and level plugs, allow oil to drain completely. Clean and refit drain plug. 3.Remove filler plug and inject new oil until oil runs out from level hole. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids Allow excess oil to drain and wipe clean. 4.Clean and refit filler and level plugs. NOTE: On later vehicles, the level and drain plugs have been deleted. The swivel pin housing is filled with grease on manufacture, for life service, and maintenance is not required. CHECK/TOP UP SWIVEL PIN HOUSING OIL 1.Ensure vehicle is level. 2.Remove level and filler plug, check oil level and top up if necessary with new oil until oil runs out from level hole. Allow excess oil to drain and wipe clean. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids 3.Clean and refit filler and level plugs.
10MAINTENANCE 12 MAINTENANCEREV: 05/99 LUBRICATE PROPELLER SHAFT UNIVERSAL AND SLIDING JOINTS 1.Clean all grease nipples on front and rear propeller shafts. 2.Using a low pressure hand grease gun, apply recommended grease See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids to grease nipples at front and rear propeller shaft universal and sliding joints. VISUALLY CHECK BRAKE, FUEL, CLUTCH HOSES/PIPES/UNIONS FOR CHAFING, LEAKS AND CORROSION CHECK EXHAUST SYSTEM FOR LEAKS, SECURITY AND DAMAGE RENEW CATALYTIC CONVERTERS See MANIFOLD AND EXHAUST SYSTEM, Repair, manifolds and exhaust system CHECK FOR FLUID LEAKS FROM POWER STEERING AND SUSPENSION SYSTEMS, HYDRAULIC PIPES AND UNIONS FOR CHAFING AND CORROSION CHECK/TIGHTEN STEERING UNIT AND STEERING ROD BALL JOINT FIXINGS, CHECK CONDITION OF BALL JOINTS AND DUST COVERSBall joints are lubricated for life during manufacture and require no further lubrication unless the rubber boot has been dislodged or damaged. All joints should be checked at specified service intervals, but more frequently if vehicle is used under arduous conditions. 1.Check for wear in joints by moving ball joint up and down vigorously. If free movement is apparent, fit a new joint assembly. See STEERING, Repair, Drop arm ball See STEERING, Repair, Track rod and See STEERING, Repair, Drag link and drag link ends CHECK/TIGHTEN FRONT AND REAR AXLE SUSPENSION LINK FIXINGS, CHECK CONDITION OF MOUNTING RUBBERS DRAIN AND CLEAN FUEL SEDIMENTER, IF FITTED The fuel sedimenter is located on a chassis side member on the RH side of vehicle near rear wheel. It increases the working life of the fuel filter by removing larger droplets of water and other matter from fuel. NOTE: On 110/130 models with a twin tank fuel system, two sedimenters may be fitted, one on each side of the vehicle chassis. 1.Slacken drain plug and allow any water to drain off.
MAINTENANCE 13 MAINTENANCE REV: 05/992.When pure diesel is emitted, retighten drain plug. 3.Disconnect fuel inlet pipe at sedimenter. Raise and support pipe above level of fuel tank to prevent fuel draining from tank. 4.Support sedimenter bowl, unscrew bolt and remove bowl. 5.Remove sedimenter element. 6.Clean all components in kerosene. 7.Fit new seals. 8.Fit element into sedimenter bowl. 9.Secure bowl to sedimenter head. 10.Fit fuel inlet pipe to sedimenter. 11.Slacken drain plug and when pure diesel is emitted, retighten plug. 12.If necessary, prime the system. See FUEL SYSTEM, Adjustment, Priming the fuel system CHECK CONDITION OF ENGINE MOUNTING RUBBERS CHECK SECURITY OF TOWING BRACKET FITTINGSCARRY OUT ROAD OR ROLLER TEST WARNING: Two wheel roller tests MUST NOT be carried out. For details of dynamometer testing. See INTRODUCTION, Information, Dynamometer testing Check the following components: 1.Engine for excessive noise. 2.Clutch for slip, judder or spin/drag. 3.Gear selection/noise - high/low range. 4.Steering for abnormal noise/effort. 5.Steering for free play. 6.All instruments, gauges and warning indicators. 7.Heater and air conditioning systems. 8.Heated rear screen. 9.Shock absorbers - ride irregularities. 10.Foot brake, on emergency stop, pulling to one side, binding and pedal effort. 11.Handbrake operation. 12.Seat reclining and latching. 13.Fully extend seat belt, check operation of retraction and latching. Inertia belts lock when snatched or vehicle on slope. 14.Road wheel balance. 15.Transmissions for vibrations. 16.Body noises, squeaks and rattles. 17.Excessive exhaust smoke. 18.Engine idle speed. 19.Endorse service record. 20.Report any unusual features of vehicle condition and additional work required. ENDORSE SERVICE RECORD
10MAINTENANCE 14 MAINTENANCEREV: 05/99 ADDITIONAL MAINTENANCE SCHEDULES Camshaft drive belt The engine timing gears are driven by a toothed rubber belt which must be renewed at intervals determined by the severity of operating conditions. In reasonable, temperate climate operation, the belt should be renewed every 120,000 km (72,000 miles) or every six years whichever occurs earlier. In adverse operating conditions, such as work in dusty atmospheres, high ambient temperatures, desert and tropical zones, renew the belt every 60,000 km (36,000 miles) or every three years, whichever occurs earlier. CAUTION: If the drive belt is not renewed at the correct interval, it could fail, resulting in serious engine damage. Oil change diesel engines If the vehicle is operated on fuel with a high sulphur content (over 1%) the oil change intervals must not exceed 5000 km (3000 miles). Anti-freeze At two yearly intervals or at the onset of the second winter, the cooling system should be drained, flushed and refilled with the required water and anti-freeze solution. Hydraulic brake fluid. It is recommended that at 40,000 km (24,000 miles) intervals or every two years, whichever is the earlier, the hydraulic brake fluid should be completely renewed. At 80,000 km (48,000 miles) intervals or every four years, whichever is the earlier, all hydraulic brake fluid seals and flexible hoses should be renewed. All working surfaces of the master cylinder and caliper cylinders should be examined and renewed where necessary.Air cleaner When the vehicle is used in dusty or field conditions or deep wading, frequent attention to the air cleaner may be required. Dampers At 60,000 km (36,000 miles) intervals remove all suspension dampers, test for correct operation, refit or renew as necessary. SPECIAL OPERATING CONDITIONS When the vehicle is operated in extremely arduous conditions or on dusty, wet or muddy terrain, more frequent attention should be paid to all servicing requirements. Additional daily or weekly attention depending on operating conditions: Check/top-up transfer box oil. Check steering rubber boots for security and condition. Renew if damaged. Check brake fluid level: Investigate cause if any fluid loss is suspected. Clean brake discs and calipers. Lubricate front and rear propeller shaft universal/sliding joints. Under tropical or severe conditions, particularly where sand is encountered, the sliding joints must be lubricated very frequently to prevent ingress of abrasive material. Every week and every maintenance inspection check tyre pressures and inspect tyre treads and side walls. Under arduous cross-country conditions the tyre pressures should be checked much more frequently, even to the extent of a daily check. Monthly Renew gearbox oil. Renew transfer box oil. Check air cleaner element and renew every 6 months or as necessary.
MAINTENANCE 15 MAINTENANCE ADDITIONAL MAINTENANCE SCHEDULES Camshaft drive belt The engine timing gears are driven by a toothed rubber belt which must be renewed at intervals determined by the severity of operating conditions. In reasonable, temperate climate operation, the belt should be renewed every 120,000 km (72,000 miles) or every six years whichever occurs earlier. In adverse operating conditions, such as work in dusty atmospheres, high ambient temperatures, desert and tropical zones, renew the belt every 60,000 km (36,000 miles) or every three years, whichever occurs earlier. CAUTION: If the drive belt is not renewed at the correct interval, it could fail, resulting in serious engine damage. Oil change diesel engines If the vehicle is operated on fuel with a high sulpher content (over 1%) the oil change intervals must not exceed 5000 km (3000 miles). Anti-freeze At two yearly intervals or at the onset of the second winter, the cooling system should be drained, flushed and refilled with the required water and anti-freeze solution. Hydraulic brake fluid. It is recommended that at 40,000 km (24,000 miles) intervals or every two years, whichever is the earlier, the hydraulic brake fluid should be completely renewed. At 80,000 km (48,000 miles) intervals or every four years, whichever is the earlier, all hydraulic brake fluid seals and flexible hoses should be renewed. All working surfaces of the master cylinder and caliper cylinders should be examined and renewed where necessary.Air cleaner When the vehicle is used in dusty or field conditions or deep wading, frequent attention to the air cleaner may be required. Dampers At 60,000 km (36,000 miles) intervals remove all suspension dampers, test for correct operation, refit or renew as necessary. SPECIAL OPERATING CONDITIONS When the vehicle is operated in extremely arduous conditions or on dusty, wet or muddy terrain, more frequent attention should be paid to all servicing requirements. Additional daily or weekly attention depending on operating conditions: Check/top-up transfer box oil. Check steering rubber boots for security and condition. Renew if damaged. Check brake fluid level: Investigate cause if any fluid loss is suspected. Clean brake discs and calipers. Lubricate front and rear propeller shaft universal/sliding joints. Under tropical or severe conditions, particularly where sand is encountered, the sliding joints must be lubricated very frequently to prevent ingress of abrasive material. Every week and every maintenance inspection check tyre pressures and inspect tyre treads and side walls. Under arduous cross-country conditions the tyre pressures should be checked much more frequently, even to the extent of a daily check. Monthly Renew gearbox oil. Renew transfer box oil. Check air cleaner element and renew every 6 months or as necessary.
ENGINE 1 ADJUSTMENT REV: 05/99 VALVE CLEARANCES - CHECK AND ADJUST Service repair no - 12.29.48 Adjust CAUTION: If the crankshaft is rotated with excessive valve clearace, it is possible that the push rods could be dislodged from the cam follower seating and fracture the cam follower slide. To prevent damage, eliminate all clearance from any loose rockers before turning the crankshaft to adjust clearances. 1.Rotate crankshaft until No.8 valve (counting from front of engine) is fully open. 2.Using a 0,20 mm (0.008 in) feeler gauge adjust clearance of No.1 valve. 3.Slacken locknut and turn adjusting screw clockwise to reduce clearance and anti-clockwise to increase clearance. Tighten locknut to 16 Nm. 4.Repeat operation for remaining tappets in the following sequence: No.3 tappet with No.6 valve fully open. No.5 tappet with No.4 valve fully open. No.2 tappet with No.7 valve fully open. No.8 tappet with No.1 valve fully open. No.6 tappet with No.3 valve fully open. No.4 tappet with No.5 valve fully open. No.7 tappet with No.2 valve fully open. 5.On completion, recheck clearances and adjust as necessary.
ENGINE 1 REPAIR CYLINDER COMPRESSION TEST Service repair no - 12.25.01 1.Start and run engine to normal operating temperature. 2.Switch off engine. 3.Disconnect spill return hose and fuel pipe from No.1 injector. 4.Remove retaining nut, release clamp and withdraw injector from cylinder head. See FUEL SYSTEM, Repair, injectors 5.Disconnect electrical lead from fuel cut-off solenoid at injection pump to prevent delivery of fuel to injectors. On vehicles fitted with a digital diesel shut-off valve (DDS) immobilisation system, disconnect DDS multi-plug. 6.Ensure injector port is clean, If necessary, crank the engine a few revolutions to remove any loose carbon. 7.Fit dummy injector, from diesel compression tester kitLRT-19-007, into the cylinder head and clamp securely in position. 8.Connect flexible hose and gauge to dummy injector as shown above. 9.Crank engine for 10-20 seconds and note reading on gauge. The gauge will indicate the compression of the cylinder and maintain the reading until the pressure release valve on the gauge is depressed. Expected readings of a crank test, with vehicle battery fully charged, compression ratio 19.5:1 should be 24 bar (348 lbf/in 2).10.Repeat test procedure for remaining clinders in turn. NOTE: A variation in compression readings between cylinders is often a better indication of an engine problem than the absolute values of compression. 11.If compression is appreciably less than correct reading, or varies by more than 10%, piston rings or valves may be worn or damaged. Low pressures in adjoining cylinders may indicate a faulty cylinder head gasket.