Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							MAINTENANCE
9
MAINTENANCE UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud or water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - V8i
1.Ensure vehicle is level. If necessary, run engine
to warm oil.
2.Disconnect battery. See Clean battery terminals.
3.Place drain tray under drain plug.
4.Remove engine oil dipstick.
5.Remove sump drain plug. Allow oil to drain
completely.
6.Fit NEW copper washer and refit drain plug.
43
Nm, 32 lbf ft.
7.Place drain tray under filter.
8.Unscrew oil filter counter-clockwise.9.Clean filter adaptor face. Coat sealing ring on
NEW filter with clean engine oil. Screw filter on
until sealing ring contacts sealing face (finger
tight), then tighten a further half turn by hand
only.DO NOTovertighten.
10.Remove engine oil filler cap. Clean inside and
outside of cap.
11.Pour in correct quantity of NEW oil to FULL
mark on dipstick.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
recommended lubricants and fluids
12.Reconnect battery, run engine and check for oil
leaks from oil filter.
13.Stop engine, allow oil to return to sump for a few
minutes, then recheck oil level and top-up if
necessary.
NOTE: Oil can symbol on dipstick must be
correct way up when viewed from LH side
of vehicle. 
						

							10MAINTENANCE
10
MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND
FLUID SCREEN - ZF
1.Ensure vehicle is level. Place drain tray under
drain plug.
2.Remove gearbox dipstick, located at rear of RH
rocker cover, to aid oil drainage. Remove drain
plug from bottom of sump and allow fluid to drain
completely.
3.Refit plug using a NEW sealing washer. Tighten
to
10 Nm, 8 lbf ft.
4.Remove and replace fluid screen.See
AUTOMATIC GEARBOX, Repair, Fluid Pan
Gasket and Screen
Refill and Check Fluid Level.
NOTE: The fluid level must checked when
fluid is COLD and engine idling in N.
5.Refill or top-up with correct quantity and grade of
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, recommended
lubricants and fluids
6.With P selected, start and run engine. Apply
footbrake, move selector slowly to position 1
then back to N. Check fluid level, this must be
between the 2 level marks on dipstick. 
						

							MAINTENANCE
11
MAINTENANCE
CHECK/TOP-UP TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery negative lead.
3.Clean area around filler/level plug.
4.Remove plug and fill gearbox with recommended
grade of oil, until oil starts to seep from filler/level
hole.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, recommended
lubricants and fluids
5.Clean any previously applied sealant from
filler/level plug.
6.Apply Hylomar sealant to threads of plug and
refit plug. Tighten to
30 Nm, 22 lbf ft.
7.Wipe away any surplus oil.
8.Reconnect battery negative lead.
RENEW TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery negative lead.
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 a suitable container 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 prior to
applying fresh Hylomar sealant. Fit plug
Tighten to
30 Nm, 22 lbf ft.
8.Fill gearbox with correct quantity and grade of oil
until oil seeps from filler level hole. Wipe away
any surplus oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended lubricants and fluids
9.Thoroughly clean filler/level plug threads prior to
applying fresh Hylomar sealant. Fit plug
Tighten to
30 Nm, 22 lbf ft.
10.Reconnect battery negative lead. 
						

							10MAINTENANCE
12
MAINTENANCE
CHECK/TOP-UP FRONT AND REAR AXLE OIL
1.Ensure vehicle is level.
2.Using a 13mm, 0.5 in square drive wrench,
remove filler/level plug from axle.
3.If necessary inject oil of recommended grade
until it reaches level hole.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
recommended lubricants and fluids
4.Clean and refit filler/level plug and wipe away
surplus oil.
RENEW FRONT AND REAR AXLE OIL
1.Site vehicle on lift or level ground. Place
container under axle to be drained.
2.Using a 13mm, 0.5 in square drive wrench,
remove drain and filler/level plugs from axle.
Allow oil to drain completely. Clean and refit
drain plug.
3.Inject new oil of recommended make and grade
until it reaches level hole.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
recommended lubricants and fluids
4.Clean and refit filler/level plug and wipe away
surplus oil.
CHECK/TOP-UP SWIVEL PIN HOUSING OIL
CAUTION: Housings with filler plug only
are filled with grease which does not
require top-up or renewing.
1.Site vehicle on lift or level ground. Clean area of
filler/level plug.
2.Remove filler/level plug and inject recommended
grade of oil until it seeps from level hole.
3.Refit filler/level plug, wipe away any surplus oil.
RENEW SWIVEL PIN HOUSING OIL
1.Site vehicle on lift or level ground. Place
container 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 recommended
grade of oil it reaches level hole.
4.Clean and refit level and filler plugs, wipe away
any surplus oil.
NOTE: On later vehicles, the level and
drain plugs have been deleted. The swivel
pin housing is filled with grease for life
service and maintenance is not required. 
						

							MAINTENANCE
13
MAINTENANCE
LUBRICATE PROPELLER SHAFT SLIDING AND
UNIVERSAL JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease, to grease nipples at front
and rear propeller shaft universal and sliding
joints.
CHECK VISUALLY BRAKE, FUEL PIPES/UNIONS
FOR CHAFING LEAKS AND CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
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 OF BALL JOINTS AND DUST COVERS
Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. This
applies ONLY if rubber boot has not been dislodged
or damaged. Joints should be checked at specified
mileage 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.
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS.
CHECK/TIGHTEN TOWING BRACKET FIXINGS. 
						

							10MAINTENANCE
14
MAINTENANCE
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out following instructions.
See
INTRODUCTION, Information, Fuel Handling
Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
The fuel line filter is located on RH chassis side
member forward of the rear wheel arch.
1.Disconnect battery negative lead.
2.Thoroughly clean area around hose
connections.
3.Position cloth around relevant union on fuel filter
to protect against fuel spray as fuel line pressure
is released.
See FUEL SYSTEM, Repair, Fuel
filter
4.Loosen 2 fuel unions and disconnect hoses from
filter canister.
5.Loosen bolt securing bracket to chassis side
member and remove filter.
Fit new filter
6.Fit a new filter and tighten bracket bolt. Ensure
direction of flow ARROW on canister faces
forward.
7.Fit inlet and outlet hoses.
30 Nm, 22 lbf ft.
8.Reconnect battery negative lead.
9.Start engine and inspect hose connections for
fuel leaks.
RENEW HEATED OXYGEN SENSORS (HO2S)
See FUEL SYSTEM, Repair, Heated Oxygen
Sensor (HO2S) - Front
and
See FUEL SYSTEM, Repair, Heated Oxygen
Sensor (HO2S) - Rear
RENEW CATALYTIC CONVERTERS
See EMISSION CONTROL, Repair, front pipe /
catalytic converter
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIRED 
						

							MAINTENANCE
15
MAINTENANCE
CARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests must be
restricted to 8 mph, 5km/hour. Do not
engage the differential lock or the vehicle
will drive off the test rig because the vehicle is in
permanent four wheel drive.
For details of dynamometer testing.
See
INTRODUCTION, Information, Dynamometer
Testing
Check following items:
1.Inhibitor switch only operates in P and N.
2.Engine for excessive noise.
3.Automatic gear selection/shift speeds.
4.Gear selection/noise - high/low range.
5.Steering for abnormal noise/effort.
6.Steering for free play.
7.All instruments, gauges and warning indicators.
8.Heater and air conditioning systems.
9.Heated rear screen.
10.Shock absorbers - ride irregularities.
11.Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
12.Park brake operation.
13.Seat reclining and latching.
14.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
15.Road wheel balance.
16.Transmission for vibrations.
17.Body noises, squeaks and rattles.
18.Excessive exhaust smoke.
19.Engine idle speed.
20.Endorse service record.
21.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORDRESET EMISSION MAINTENANCE REMINDER -
USA
The emission maintenance reminder is designed to
activate at 82,500 and 165,000 miles respectively and
will illuminate a Service Engine RED warning light in
instrument binnacle.
The emission maintenance reminder must be reset
after required maintenance has been carried out and
a new tamperproof label fitted by a Land Rover of
North America dealer. This emission maintenance
reminder is part of the Emission Control System
Reset
1.The control unit is located in the passenger
footwell.
2.Identify control unit and remove from plug.
3.Remove tamperproof label to reveal access hole
for resetting.
4.Place a thin metallic probe into access hole and
momentarily electrically short between reset pins
inside unit.
RECOMMENDED SERVICE ITEMS
Refer Service Schedule sheets for intervals.
Clean sunroof drain tubes, clean and lubricate guide
rails and slides.
Renew the hydraulic brake fluid.
See BRAKES,
Repair, Brake System Bleed
Renew all hydraulic brake fluid, seals, brake servo
filter and flexible hoses.
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. 
						

							MAINTENANCE
1
SPECIFICATIONS, TORQUE TORQUE SETTINGS
Nm lbf ft
Road wheel nuts 130.............................................................. 95
Spark plugs 20...................................................................... 15
Automatic gearbox drain plug 10.......................................... 8
Transfer box drain/filler plugs 30........................................... 22
Fuel filter hose/pipe unions 30.............................................. 22
Steering box drop arm nut 175................................................ 130
Steering box to chassis 80.................................................... 60
Steering box tie-rod 80.......................................................... 60
Front radius arm to chassis 200.............................................. 150
Rear radius arm to axle 175.................................................... 130
Bottom link to axle/chassis 175............................................... 130 
						

							4.0 V8
1
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
1.Disconnect battery negative lead.
2.Remove drive plate.
See ENGINE 4.0 V8,
Repair, Drive Plate
3.Remove oil seal from location.
CAUTION: Do not damage seal location or
running surface on crankshaft.Refit
4.Ensure both seal location and running surface
on crankshaft are clean.
5.Ensure mating faces of flywheel and crankshaft
are clean.
6.Lubricate seal guideLRT-12-095with clean
engine oil. Position over crankshaft boss.
7.Lubricate oil seal lip.
8.Position seal squarely. Remove guide.
9.Drift seal into location usingLRT-12-091.
10.Fit drive plate.
See ENGINE 4.0 V8, Repair,
Drive Plate
11.Reconnect battery negative lead. 
						

							12ENGINE
2
REPAIR DRIVE PLATE
Service repair no - 12.53.13
Remove
1.Remove gearbox and transfer box assembly.
See AUTOMATIC GEARBOX, Repair,
gearbox and transfer box assembly
2.Remove 4 clamp ring bolts. Collect clamp ring.
3.Remove flexible drive plate/starter ring gear
assembly from hub aligner.
4.Remove 6 screws from hub aligner. Remove hub
aligner from crankshaft. Collect shim.
5.Check drive plate for distortion or cracks. Check
starter ring gear for chipped or broken teeth. If
either component shows signs of damage, fit a
new assembly.Refit
6.Ensure all mating surfaces are clean.
7.Fit shim and hub aligner to crankshaft.
8.Fit hub aligner screws and tighten to
85 Nm, 63
lbf ft.
9.Fit drive plate and clamp ring.
10.Fit clamp ring bolts and tighten to
45 Nm, 33 lbf
ft.
NOTE: It is only necessary to reshim the
drive plate when a new crankshaft or hub
aligner is fitted.
11.Fit gearbox and transfer box assembly.
See
AUTOMATIC GEARBOX, Repair, gearbox
and transfer box assembly