Land Rover Defender 99my Owners Handbook Aus Rover

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SECTION 5
Workshop maintenance
Section Contents Page
Workshop maintenance 101...........................
Engine oil renewal 105....................................
Engine oil filter renewal 106............................
Fuel filter renewal 108....................................
Fuel sedimenter draining 109.........................
Air cleaner element renewal 110.....................
Main gearbox oil renewal 111.........................
Transfer gearbox oil renewal 112....................
Axle oil renewal 113........................................
Brake pad/disc check 114...............................
Handbrake check/adjustment 115...................
Propeller shaft lubrication 115........................ 
						

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							Workshop maintenance
101 WORKSHOP MAINTENANCE
It is recommended that the maintenance
procedures covered in this section of the
handbook, should only be carried out by
qualified personnel in a fully equipped
workshop; preferably an authorised Land
Rover dealer. However, if the vehicle is being
operated in a remote area, where full
workshop facilities are not available, some
maintenance can be carried out, provided that
it is completed in safe conditions by
experienced personnel.
WARNING
DO NOT carry out any maintenance in dusty,
damp or dirty conditions.
NOTE:Some of the servicing procedures
require specialised knowledge and equipment,
and therefore MUST be carried out by a
qualified person, familiar with the
maintenance and safety procedures practised
by Land Rover dealers. These NECESSARY
procedures are NOT covered in this handbook
and should be referred to a Land Rover dealer.Servicing schedules
In normal operating conditions, servicing
should be carried out at intervals of 10,000
km (6,000 miles) or every six months,
whichever is sooner.
IMPORTANT INFORMATION
Special operating conditions
When a vehicle is operated in extremely
arduous conditions, or on dusty, wet or
muddy terrain, more frequent attention
must be paid to servicing requirements.
For example; if your vehicle experiences
deep wading conditions, even DAILY
servicing could be necessary to ensure
the continued safe and reliable operation
of the vehicle.
Contact a Land Rover dealer for advice. 
						

							Workshop maintenance
102 Emission control
Your vehicle is fitted with various items of
emission control equipment, designed to meet
specific territorial requirements.
You should be aware that unauthorised
replacement, modification or tampering with
this equipment by an owner or motor vehicle
repairer, may be unlawful and subject to legal
penalties.
In addition, engine settings must NOT be
tampered with. These have been established
to ensure that your vehicle complies with
stringent exhaust emission regulations.
Incorrect engine settings may adversely affect
exhaust emissions, engine performance and
fuel consumption, as well as causing high
temperatures, which will result in damage to
the vehicle.
Replacement parts
It is essential that only Land Rover approved
parts are used, safety features embodied in
the vehicle may be impaired if other,
non-approved parts are used. In certain
territories, legislation prohibits the fitting of
parts not to the manufacturers specification.
WARNING
The fitting of parts of inferior quality, or the
carrying out of non-approved alterations or
conversions, may be dangerous and could
affect the safety of the vehicle and
occupants. It could also invalidate the terms
and conditions of the vehicle warranty.Road testing on dynamometers
(rolling roads)
WARNING
Because your vehicle is equipped with
permanent four-wheel drive, it is essential
that any dynamometer testing is carried out
ONLY by a qualified person, familiar with
the dynamometer testing and safety
procedures practised by Land Rover
dealers. Contact your Land Rover dealer for
further information. 
						

							Workshop maintenance
103 SAFETY IN THE GARAGE
Whenever you carry out maintenance on
your vehicle, the following safety
precautions should be observed at all times.
·ALWAYS keep hands, tools and items of
clothing clear of all drive belts and pulleys
whilst they are in operation.
·DO NOT touch exhaust or cooling system
components until they are cool.
·DO NOT touch electrical leads or
components with the starter switch turned
on.
·NEVER leave the engine running in an
unventilated area; exhaust gases are
poisonous and contain carbon monoxide,
which can cause unconsciousness and
can be fatal.
·DO NOT work beneath the vehicle with the
lifting jack as the only means of support.
·Ensure sparks and naked lights are kept
away from the engine and battery
compartments.
·DO NOT use any lubricants, solvents or
sealants etc, without first reading any
warnings and instructions supplied with
these substances; they could be harmful if
improperly used.
WARNING
Remember, cooling fans and air
conditioning system condenser fans (if
fitted), may continue to operate after the
engine is switched off. Always wait until the
fans have completely stopped moving before
working in the engine compartment.Fuel system safety
Fuel vapour is highly flammable and in
confined spaces, is also very explosive and
toxic. When fuel evaporates, it produces 150
times its own volume in vapour and when
mixed with air, becomes an easily ignitable
mixture; consequently even a small spillage is
very dangerous.
It is recommended that you always have a
FOAM, CO
2GAS, or POWDER type fire
extinguisher close at hand when working with
fuel or the fuel system.
ALWAYS disconnect the battery negative lead
BEFORE carrying out work on the fuel system.
WARNING
It is imperative that the battery is
disconnected BEFORE and not during any
work on the fuel system, as arcing at the
battery terminal could ignite fuel vapour in
the atmosphere.
Whenever fuel is being handled, transferred
or stored, or when carrying out work on the
fuel system, all forms of ignition MUST be
extinguished or removed, any lighting being
used MUST be flameproof and kept clear of
the fuel. 
						

							Workshop maintenance
104 Poisonous liquids
Most liquids and lubricants used in motor
vehicles are poisonous and should not be
consumed or brought into contact with open
wounds. These include; battery acid,
anti-freeze, brake, clutch and power steering
fluid, as well as petrol, diesel, engine oil and
windscreen washer additives.
For your own safety, ALWAYS read and obey
all instructions printed on labels and
containers.
Used engine oil
Prolonged contact with engine oil can cause
serious skin disorders, including dermatitis
and skin cancer. ALWAYS wash thoroughly
after contact.
It is illegal to pollute drains, water courses or
soil with toxic chemicals such as used engine
oil. ALWAYS dispose of vehicle liquids and
lubricants at authorised waste disposal sites,
or at garages which provide facilities for the
receipt of discharged batteries, used engine
oil and toxic chemicals. If in doubt, contact
your Local Authority for advice.
PROTECT THE ENVIRONMENT! 
						

							Workshop maintenance
105 ENGINE OIL RENEWAL
NOTE:For engine oil check & top-up see
Owner maintenance.
WARNING
DO NOT attempt to drain the engine sump if
the engine has been running for some time,
the engine oil will be hot and may cause
severe scalding.
With the vehicle resting on firm, level ground,
run the engine for a few minutes so that the
oil will drain more easily. Turn the starter
switch to position 0 and disconnect the
battery negative lead.
Remove the oil filler cap and position a
suitable container under the oil drain plug
(arrowed) to collect the used oil. Clean the
area around the drain plug.
·Remove the drain plug and discard the
sealing washer. Allow the oil to drain
completely.
NOTE:If, by necessity, this procedure is
being carried out in dusty or sandy
conditions, refit the drain plug as soon as the
main bulk of the oil has drained.
·Clean the draining plug and fit with a new
sealing washer.
·Refit and tighten the drain plug to 23 Nm.
Refill the sump with fresh oil of the correct
specification (see General data). Refit the
filler cap and let the vehicle stand for five
minutes to allow the oil to drain back into the
sump. Check the oil level using the dipstick
(as described in Owner maintenance) and top
up until the correct level is obtained.
Reconnect the battery.
·DO NOT use oil previously drained from
the engine.
·DO NOT OVERFILL! 
						

							Workshop maintenance
106 ENGINE OIL FILTER RENEWAL
To prevent any possibility of air locks in the oil
pump, it is recommended that filter renewal is
carried out AFTER the engine oil has been
changed.
·Turn the starter switch to position 0 and
disconnect the battery negative lead.
·Remove the 3 bolts securing the engine
acoustic cover and remove the cover.
·Release the clip and disconnect the
breather hose (2) from the camshaft
cover.
·Release the clips and disconnect air flow
meter (3) from the air cleaner (4).
·Disconnect the multi-plug from the air
flow meter.
·Loosen the clip screw and remove air inlet
hose (5) from the turbocharger.
·Remove the 3 bolts (6) securing the
exhaust manifold heat shield and remove
the shield.
·Clean the area around the head of the filter
and place a suitable container beneath the
filter. 
						

							Workshop maintenance
107
·Using a strap wrench, unscrew the filter
(7) and discard it safely.
·Clean the mating surface of the filter head.
·Lubricate the sealing ring (7) of the new
filter, with clean engine oil of the correct
specification (see General data).
·Screw the filter on clockwise until the
rubber washer touches up against the
machined face, then tighten a further half
turn using hand pressure only. DO NOT
OVERTIGHTEN.
·Connect the battery negative lead and run
the engine at a fast idle for five minutes.
·Check the filter for leaks.
·Stop the engine and let the vehicle stand
for five minutes to let the oil drain back
into the sump. Check the oil level (see
Owner maintenance) and top up if
necessary.
·Secure the exhaust manifold heat shield
with the 3 bolts.
·Position the air inlet hose to the
turbocharger and tighten clip screw.
·Connect the air flow meter to the air
cleaner and secure clips.
·Connect the air flow meter multi-plug.
·Connect the breather hose and secure with
the clip.
·Secure the engine acoustic cover with the
3 bolts.