Land Rover Defender V8i Workshop Supplement Rover Manual

							10MAINTENANCE
4
MAINTENANCE UNDER BONNET MAINTENANCE
CHECK COOLING/HEATER SYSTEMS
Check cooling/heater systems for leaks and hoses for
security and condition.
Cooling system hoses should be changed at first
signs of deterioration.
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK BRAKE SERVO HOSE FOR SECURITY
AND CONDITION
CHECK FUEL EVAPORATIVE LOSS CONTROL
SYSTEM FOR LEAKS
CHECK FUEL FILLER CAP SEAL FOR LEAKSCHECK IGNITION WIRING
Check H.T. leads for fraying, chafing and
deterioration. Ensure H.T. leads are correctly clipped
in place. 
						

							MAINTENANCE
5
MAINTENANCE
RENEW SPARK PLUGS - V8i
Clean, adjust and renew
1.Take great care when fitting spark plugs not to
cross-thread plug, otherwise costly damage to
cylinder head will result.
2.Clean or replace spark plugs as applicable.
3.It is essential that correct type of spark plugs are
fitted.
4.Incorrect grade of plugs may lead to piston
overheating and engine failure.
Remove
5.Disconnect battery negative lead. Disconnect
H.T. leads from spark plugs.
6.Remove plugs and washers.
Refit
7.Inspect spark plugs, renew as necessary.
8.Set plug gaps.
CAUTION: Use correct type and grade of
plug.
9.Apply anti-seize to plug threads. Fit spark plugs.
Tighten to
15 Nm (11 lbf.ft).
10.Connect and route spark plug leads correctly.
Failure to route H.T. leads correctly may result in
cross-firing between two closely fitted leads
which are consecutive in firing order.
CAUTION: When pushing leads onto
plugs, ensure that shrouds are firmly
seated.
CLEAN PLENUM CHAMBER VENTILATION
PASSAGEWAY - V8i
CAUTION: Care must be taken to prevent
debris from passageway passing beyond
throttle butterfly disc.
WARNING: Safety glasses must be worn
when performing this operation. Ensure
that debris is not blown into atmosphere
which could be harmful to other persons close by.
1.Disconnect battery negative lead.
2.Release hose clamp and remove hose from
plenum chamber inlet.
3.Remove crankcase ventilation hose from side of
plenum chamber.
4.Insert a piece of lint free cloth down throttle
butterfly bore to prevent debris passing throttle
butterfly.
5.Place a cloth over tube protruding from side of
plenum from which ventilation hose was
removed to prevent debris from passageway
being blown into atmosphere.
6.Use a compressed air line with a slim bent
nozzle to enable passageway to be cleaned out
from within throttle butterfly bore.
7.Any remaining matter can be dislodged using
soft bent wire or pipe cleaner. Finally blow out
passageway again to remove remaining debris.
8.Remove small T piece between crankcase
ventilation hoses and check it is free from
blockages, clean as necessary.
9.Refit T piece and hoses, tighten hose clamps
securely. 
						

							10MAINTENANCE
6
MAINTENANCE
RENEW AIR CLEANER ELEMENT - V8i
To renew air cleaner element - V8i
See FUEL SYSTEM, Repair, Air Cleaner
RENEW CHARCOAL CANISTER AND PURGE
CONTROL VALVE - V8i
Renew charcoal canister and purge control valve.
See EMISSION CONTROL, Repair, EVAP canister
and purge control valve
CHECK AUXILIARY DRIVE BELT - V8i
1.Check condition of drive belt, renew a belt that
shows signs of wear, splitting or oil
contamination.
2.Check belt length indicator,belt MUST be
renewed before indicator reaches RH end of
slot.
RENEW AUXILIARY DRIVE BELT - V8i
Renew drive belt.See ELECTRICAL, Repair,
Auxiliary drive Belt
CHECK/TOP-UP AUTOMATIC TRANSMISSION
FLUID LEVEL
NOTE: Transmission fluid level is checked
when fluid is cold with engine idling in N
(neutral).
1.Ensure vehicle is on level ground.
2.Check fluid level registers between the 2 level
marks on dipstick.
3.Top-up to high mark on dipstick using the correct
grade of transmission fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
recommended lubricants and fluids 
						

							MAINTENANCE
7
MAINTENANCE
CHECK/TOP-UP COOLING SYSTEM
To prevent corrosion of aluminium alloy engine parts it
is imperative that cooling system is filled with a
solution of water and phosphate free anti-freeze, at all
times.Never fill or top-up with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
1.First turn filler cap slowly counter-clockwise to its
stop, pause and allow all pressure to escape.
Press down and continue to turn until cap is
removed.
2.When engine is cold, expansion tank should be
approximately half full with coolant.
3.If necessary, top-up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
4.When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements.
See COOLING SYSTEM,
Adjustment, Coolant RequirementsCHECK/TOP-UP POWER STEERING FLUID
RESERVOIR
1.Clean area of fluid reservoir cap and remove
cap.
2.Check that fluid level is not below lower mark on
dipstick.
3.Top-up to high mark on dipstick using
transmission fluid.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
recommended lubricants and fluids 
						

							10MAINTENANCE
8
MAINTENANCE
CHECK/ TOP-UP BRAKE FLUID RESERVOIR
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
1.Clean area of filler cap and side of reservoir.
2.Check fluid level in reservoir by observing level
through translucent side. Level must be above
MIN mark.
CAUTION: If level is below MIN mark,
check braking system for possibility of
fluid leakage.
3.Remove filler cap and top-up to MAX mark with
NEW brake fluid of the correct specification from
a sealed container.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
recommended lubricants and fluids
4.Refit filler cap.
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.
CHECK/ADJUST STEERING BOX
1.Check steering box for fluid leaks.
2.Check that there is no backlash in steering box
in straight ahead position. Adjust steering box if
necessary.
See STEERING, Adjustment,
Power Steering Box - adjust 
						

							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.
Tighten to
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 transfer gearbox
and assist draining.
6.Remove drain plug and sealing washer and
allow oil to drain.
7.Thoroughly clean drain plug threads prior to
applying fresh Hylomar sealant. Fit plug and
new sealing washer 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 and area surrounding
filler/level plug is clean.
2.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.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 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.