Land Rover Defender Workshop Rover Manual

							10MAINTENANCE
10 MAINTENANCE
NOTE:
Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
maintenance, orremove andrefit procedures are
required, itmay benecessary toremove the
undertray and/orintegral accesspanels
See
CHASSIS ANDBODY, Repair, Frontundertray
or
SeeCHASSIS ANDBODY, Repair, Rearundertray
RENEW ENGINE OILAND FILTER
1. Ensure vehicleislevel.
2. Run engine towarm oil,switch offignition.
3. Disconnect battery.
4. Place suitable draintrayunder sumpdrainplug.
5.Remove drainplugfrom sump andallow oilto
drain completely.
6. Fitnew sealing washer, replaceplugandtighten
to
35 Nm (26lbf/ft).
7.Place draintrayunder oilfilter.
8. Unscrew filteranti-clockwise, usingastrap
wrench ifnecessary.
9. Clean mating faceofoil filter adaptor.
10. Coat rubber sealing washer ofnew filter with
clean engine oil.
11. Screw filteronclockwise untilsealing washer
touches adaptormatingface,tighten afurther
half turn byhand only.DONOT overtighten.
12. Clean andremove fillercapfrom rocker cover.
13. Pour incorrect quantity andgrade ofnew oil
from asealed container.
SeeLUBRICANTS,
FLUIDS ANDCAPACITIES, Information,
Recommended lubricantsandfluids
14.Check thatoillevel isbetween upperandlower
marks ondipstick. DONOT fillabove upper
mark.
15. Firmly replace fillercap.
16. Reconnect battery,runengine andcheck oilfilter
for leaks.
17. Stop engine, allowoiltorun back intosump fora
few minutes andcheck oillevel again. Topupif
necessary.   
						

							MAINTENANCE11
MAINTENANCE
RENEW
GEARBOX OIL
1. Ensure vehicleislevel.
2. Place suitable trayunder gearbox.
3. Disconnect battery.
4.Clean areaaround filler/level plugs.
5. Remove bothplugs andallow oiltodrain
completely.
WARNING: Whendraining gearbox, care
should betaken toensure thatoilisnot
hot aspersonal scaldingcouldresult.
6. Refit drain plugandtighten to
30Nm (22lbf/ft).
7.Inject newoilinto gearbox untilitruns outoffiller
hole. Allow excess oiltodrain andwipe clean.
SeeLUBRICANTS, FLUIDSAND
CAPACITIES, Information,Recommended
lubricants andfluids
8.Refit filler/level plugandtighten to30Nm (22
lbf/ft).
9. Reconnect battery.
RENEW TRANSFER GEARBOXOIL
1. Ensure vehicleislevel.
2. Disconnect battery.
3. Clean areaaround filler/level anddrain plugs.
WARNING: Whendraining gearboxcare
should betaken toensure thatoilisnot
hot aspersonal scaldingcouldresult.
4.Place suitable trayunder transfer gearbox.
5. Remove filler/level plugtovent gearbox and
assist draining.
6. Remove drainplugandallow oiltodrain.
7. Thoroughly cleandrainplugthreads andapply
fresh Hylomar sealant.
8. Refit drain plugandtighten to
30Nm (22lbf/ft).
9.Inject newoilofcorrect quantity andgrade into
gearbox untiloilruns outfrom filler/level hole.
Allow excess oiltodrain andwipe clean.
See
LUBRICANTS, FLUIDSANDCAPACITIES,
Information, Recommended lubricantsand
fluids
10. Thoroughly cleanfiller/level plugandapply fresh
Hylomar sealant.
11. Refit plugandtighten to
30Nm (22lbf/ft).
12. Reconnect battery.
CHECK/TOP UPTRANSFER GEARBOXOIL
1. Ensure vehicleislevel.
2. Disconnect battery.
3. Clean areaaround filler/level plug.
4. Remove plug,check oillevel andtopupif
necessary withcorrect gradeofoil,
See
LUBRICANTS, FLUIDSANDCAPACITIES,
Information, Recommended lubricantsand
fluids
until oilruns outfrom filler/level hole.
Allow excess oiltodrain andwipe clean.
5. Thoroughly cleanfiller/level plugthreads and
apply freshHylomar sealant.
6. Refit plugandtighten to
30Nm (22lbf/ft).
7.Reconnect battery.    
						

							10MAINTENANCE
12 MAINTENANCE
RENEW
FRONTANDREAR AXLEOIL
1. Ensure vehicleislevel andplace suitable tray
under axletobe drained.
2. Using 13mm square drivewrench, removedrain
and filler/level plugsfromaxleandallow oilto
drain completely.
3. Clean andrefitdrain plug.
A-Front andrear axle, 90models, front,110/130
models. B-Rear axle,110/130 models.
4. Inject newoil,
SeeLUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended lubricantsandfluids
until it
runs outfrom filler/level hole.Allow excess oilto
drain andwipe clean.
5. Clean andrefitfiller/level plug.
CHECK/TOP UPFRONT ANDREAR AXLE
1. Ensure vehicleislevel.
2. Using 13mm square drivewrench, remove
filler/level plug. 3.
Ifnecessary injectnewoiluntil oilruns outfrom
filler/level hole.Allow excess oiltodrain and
wipe clean.
SeeLUBRICANTS, FLUIDSAND
CAPACITIES, Information,Recommended
lubricants andfluids
4.Clean andrefitfiller/level plug.
RENEW SWIVEL PINHOUSING OIL
1. Ensure vehicleislevel andplace suitable tray
under swivel tobe drained.
2. Remove drainandlevel plugs, allowoiltodrain
completely. Cleanandrefitdrain plug.
3.Remove fillerplug andinject newoiluntil oilruns
out from level hole.
SeeLUBRICANTS,
FLUIDS ANDCAPACITIES, Information,
Recommended lubricantsandfluids
Allow
excess oiltodrain andwipe clean.
4. Clean andrefitfiller andlevel plugs.
NOTE: Onlater vehicles, thelevel and
drain plugs havebeen deleted. Theswivel
pin housing isfilled withgrease on
manufacture, forlife service, andmaintenance is
not required.
CHECK/TOP UPSWIVEL PINHOUSING OIL
1. Ensure vehicleislevel.
2. Remove levelandfiller plug, check oillevel and
top upifnecessary withnew oiluntil oilruns out
from level hole. Allow excess oiltodrain and
wipe clean.
SeeLUBRICANTS, FLUIDSAND
CAPACITIES, Information,Recommended
lubricants andfluids
3.Clean andrefitfiller andlevel plugs.   
						

							MAINTENANCE13
MAINTENANCE
LUBRICATE
PROPELLER SHAFTUNIVERSAL
AND SLIDING JOINTS
1. Clean allgrease nipples onfront andrear
propeller shafts.
2.Using alow pressure handgrease gun,apply
recommended grease
SeeLUBRICANTS,
FLUIDS ANDCAPACITIES, Information,
Recommended lubricantsandfluids
togrease
nipples atfront andrear propeller shaftuniversal
and sliding joints.
VISUALLY CHECKBRAKE, FUEL,CLUTCH
HOSES/PIPES/UNIONS FORCHAFING, LEAKS
AND CORROSION
CHECK EXHAUST SYSTEMFORLEAKS,
SECURITY ANDDAMAGE
RENEW CATALYTIC CONVERTERS
See
MANIFOLD ANDEXHAUST SYSTEM,Repair,
manifolds andexhaust system
CHECKFORFLUID LEAKS FROMPOWER
STEERING ANDSUSPENSION SYSTEMS,
HYDRAULIC PIPESANDUNIONS FORCHAFING
AND CORROSION
CHECK/TIGHTEN STEERINGUNITANDSTEERING
ROD BALL JOINT FIXINGS, CHECKCONDITION
OF BALL JOINTS ANDDUST COVERS Ball
joints arelubricated forlife during manufacture
and require nofurther lubrication unlesstherubber
boot hasbeen dislodged ordamaged. Alljoints should
be checked atspecified serviceintervals, butmore
frequently ifvehicle isused under arduous conditions.
1. Check forwear injoints bymoving balljoint up
and down vigorously. Iffree movement is
apparent, fitanew jointassembly.
See
STEERING, Repair,Droparmball See
STEERING, Repair,Trackrodand See
STEERING, Repair,Draglinkand drag link
ends
CHECK/TIGHTEN FRONTANDREAR AXLE
SUSPENSION LINKFIXINGS, CHECKCONDITION
OF MOUNTING RUBBERS
DRAIN ANDCLEAN FUELSEDIMENTER, IF
FITTED The fuelsedimenter islocated onachassis side
member onthe RH side ofvehicle nearrearwheel. It
increases theworking lifeofthe fuel filter byremoving
larger droplets ofwater andother matter fromfuel.
NOTE: On110/130 modelswithatwin tank
fuel system, twosedimenters maybe
fitted, oneoneach sideofthe vehicle
chassis.
1. Slacken drainplugandallow anywater todrain
off.    
						

							10MAINTENANCE
14 MAINTENANCE
2.
When purediesel isemitted, retighten drain
plug.
3. Disconnect fuelinlet pipe atsedimenter. Raise
and support pipeabove leveloffuel tank to
prevent fueldraining fromtank.
4.Support sedimenter bowl,unscrew boltand
remove bowl.
5. Remove sedimenter element.
6. Clean allcomponents inkerosene.
7. Fitnew seals.
8. Fitelement intosedimenter bowl.
9. Secure bowltosedimenter head.
10. Fitfuel inlet pipe tosedimenter.
11. Slacken drainplugandwhen purediesel is
emitted, retighten plug.
12. Ifnecessary, primethesystem.
See FUEL SYSTEM, Adjustment, Priming
the fuel system
CHECK CONDITION OFENGINE MOUNTING
RUBBERS CHECK SECURITY OFTOWING BRACKET
FITTINGS CARRY
OUTROAD ORROLLER TEST
WARNING: Twowheel rollertestsMUST
NOT becarried out.
For details ofdynamometer testing.
See
INTRODUCTION, Information,Dynamometer
testing
Check thefollowing components:
1. Engine forexcessive noise.
2. Clutch forslip, judder orspin/drag.
3. Gear selection/noise -high/low range.
4. Steering forabnormal noise/effort.
5. Steering forfree play.
6. Allinstruments, gaugesandwarning indicators.
7. Heater andairconditioning systems.
8. Heated rearscreen.
9. Shock absorbers -ride irregularities.
10. Foot brake, onemergency stop,pulling toone
side, binding andpedal effort.
11. Handbrake operation.
12. Seat reclining andlatching.
13. Fully extend seatbelt,check operation of
retraction andlatching. Inertiabeltslockwhen
snatched orvehicle onslope.
14. Road wheel balance.
15. Transmissions forvibrations.
16. Body noises, squeaks andrattles.
17. Excessive exhaustsmoke.
18. Engine idlespeed.
19. Endorse servicerecord.
20. Report anyunusual features ofvehicle condition
and additional workrequired.
ENDORSE SERVICERECORD  
						

							MAINTENANCE15
MAINTENANCE
ADDITIONAL
MAINTENANCE SCHEDULES
Camshaft drivebelt
The engine timinggearsaredriven byatoothed
rubber beltwhich mustberenewed atintervals
determined bythe severity ofoperating conditions. In
reasonable, temperateclimateoperation, thebelt
should berenewed every120,000 km(72,000 miles)
or every sixyears whichever occursearlier.
In adverse operating conditions, suchaswork industy
atmospheres, highambient temperatures, desertand
tropical zones,renewthebelt every 60,000 km
(36,000 miles)orevery threeyears, whichever occurs
earlier.
CAUTION: Ifthe drive beltisnot renewed
at the correct interval, itcould fail,
resulting inserious enginedamage.
Oil change dieselengines
If the vehicle isoperated onfuel with ahigh sulpher
content (over1%)theoilchange intervals mustnot
exceed 5000km(3000 miles).
Anti-freeze At two yearly intervals oratthe onset ofthe second
winter, thecooling systemshouldbedrained, flushed
and refilled withtherequired waterandanti-freeze
solution.Hydraulic brakefluid.
It is recommended thatat40,000 km(24,000 miles)
intervals orevery twoyears, whichever isthe earlier,
the hydraulic brakefluidshould becompletely
renewed. At 80,000 km(48,000 miles)intervals orevery four
years, whichever isthe earlier, allhydraulic brakefluid
seals andflexible hosesshould berenewed. All
working surfaces ofthe master cylinder andcaliper
cylinders shouldbeexamined andrenewed where
necessary. Air
cleaner
When thevehicle isused industy orfield conditions or
deep wading, frequent attention tothe aircleaner may
be required.
Dampers At 60,000 km(36,000 miles)intervals removeall
suspension dampers,testforcorrect operation, refitor
renew asnecessary.
SPECIAL OPERATING CONDITIONS
When thevehicle isoperated inextremely arduous
conditions oron dusty, wetormuddy terrain, more
frequent attention shouldbepaid toall servicing
requirements.Additional dailyorweekly attention depending on
operating conditions:
Check/top-up transferboxoil.
Check steering rubberbootsforsecurity and
condition. Renewifdamaged.
Check brakefluidlevel: Investigate causeifany fluid
loss issuspected.
Clean brakediscsandcalipers.
Lubricate frontandrear propeller shaft
universal/sliding joints.Under tropical orsevere
conditions, particularly wheresandisencountered,
the sliding jointsmustbelubricated veryfrequently to
prevent ingressofabrasive material.
Every weekandevery maintenance inspectioncheck
tyre pressures andinspect tyretreads andside walls.
Under arduous cross-country conditionsthetyre
pressures shouldbechecked muchmorefrequently,
even tothe extent ofadaily check.
MonthlyRenew gearbox oil.
Renew transfer boxoil.
Check aircleaner element andrenew every6months
or as necessary.  
						

							ENGINE1
ADJUSTMENT
VALVE
CLEARANCES -CHECK ANDADJUST
Service repairno-12.29.48
Adjust
WARNING: Ifthe crankshaft isrotated with
excessive valveclearace, itis possible
that thepush rodscould bedislodged
from thecam follower seatingandfracture the
cam follower slide.Toprevent damage, eliminate
all clearance fromanyloose rockers before
turning thecrankshaft toadjust clearances.
1. Rotate crankshaft untilNo.8 valve (counting from
front ofengine) isfully open.
2.Using a0,20 mm(0.008 in)feeler gauge adjust
clearance ofNo.1 valve.
3. Slacken locknutandturn adjusting screw
clockwise toreduce clearance and
anti-clockwise toincrease clearance. Tighten
locknut to
16Nm (12lbf/ft).
4.Repeat operation forremaining tappetsinthe
following sequence:
No.3 tappet withNo.6 valve fullyopen.
No.5 tappet withNo.4 valve fullyopen.
No.2 tappet withNo.7 valve fullyopen.
No.8 tappet withNo.1 valve fullyopen.
No.6 tappet withNo.3 valve fullyopen.
No.4 tappet withNo.5 valve fullyopen.
No.7 tappet withNo.2 valve fullyopen.
5. On completion, recheckclearances andadjust
as necessary.   
						

							ENGINE1
REPAIR
CYLINDER
COMPRESSION TEST
Service repairno-12.25.01
1. Start andrunengine tonormal operating
temperature.
2. Switch offengine.
3. Disconnect spillreturn hoseandfuelpipe from
No.1 injector.
4. Remove retaining nut,release clampand
withdraw injectorfromcylinder head.
SeeFUEL
SYSTEM, Repair,injectors
5.Disconnect electricalleadfrom fuelcut-off
solenoid atinjection pumptoprevent delivery of
fuel toinjectors. Onvehicles fittedwithadigital
diesel shut-off valve(DDS) immobilisation
system, disconnect DDSmulti-plug.
6. Ensure injector portisclean, Ifnecessary, crank
the engine afew revolutions toremove any
loose carbon.
7.Fitdummy injector, fromdiesel compression
tester kitLRT-19-007 ,into thecylinder headand
clamp securely inposition.
8. Connect flexiblehoseandgauge todummy
injector asshown above.
9. Crank engine for10-20 seconds andnote
reading ongauge. Thegauge willindicate the
compression ofthe cylinder andmaintain the
reading untilthepressure releasevalveonthe
gauge isdepressed.
Expected readingsofacrank test,withvehicle
battery fullycharged, compression ratio19.5:1
should be24bar (348 lbf/in2
). 10.
Repeat testprocedure forremaining clindersin
turn.
NOTE: Avariation incompression
readings betweencylinders isoften a
better indication ofan engine problem
than theabsolute valuesofcompression.
11. Ifcompression isappreciably lessthan correct
reading, orvaries bymore than10%, piston
rings orvalves maybeworn ordamaged.
Low pressures inadjoining cylindersmay
indicate afaulty cylinder headgasket.   
						

							12ENGINE
2 REPAIR
ENGINE
OILPRESSURE TEST
Service repairno-12.90.09/01
WARNING: Usesuitable exhaust
extraction equipment ifan engine testis
being carried outinaworkshop.
WARNING: Ifvehicle hasbeen running,
engine wilbehot; care must betaken
when fitting testequipment toprevent
personal injury.
1. Check thatengine lubricant isto correct level.
2. Remove oilpressure switch.
3.Connect pressure testgauge LRT-12-052A ,as
shown.
4. Start andrunengine tonormal operating
temperature.
5. With engine running atidle check oilpressure,
which should read1.76bar(25.87 lbf/in2
). 6.
Ifpressure islow itcan becaused bythe
following:- Thin ordiluted oil.
Low oilinsump.
Choked oilstrainer.
Faulty oilpressure reliefvalve.
Excessively wornordamaged oilpump
displacement gears.
Excessive crankshaft bearingclearance.
7. Ifexcessive pressureisindicated itcan be
caused by:-
Overfilling enginewithlubricant.
Sticking oilpressure reliefvalve.
Blockage inbreather system.  
						

							ENGINE3
REPAIR
ENGINE Service
repairno-12.41.01
Remove
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures arerequired, itmay
be necessary toremove theundertray and/or
integral accesspanels.
SeeCHASSIS ANDBODY, Repair, Front
undertray
orSee CHASSIS ANDBODY, Repair,
Rear undertray
CAUTION: Sealallexposed pipeends
against ingress ofdirt after disconnection.
1. Ensure vehicleislevel andapply parkbrake.
2. Disconnect battery.
NOTE:Thevehicle maybefitted withan
alarm andimmobilisation systemusinga
battery backed-up alarmsounder.
SeeELECTRICAL, Repair,battery
3.Remove bonnet.
4. Remove cabletiessecuring gearboxharnessto
breather pipes.
5. Disconnect harnessfromdifflock andreverse
light switches.
6. Manouvre harnessintoengine bay.
7. Remove aircleaner.
See FUEL SYSTEM,
Repair, Aircleaner
8.Remove radiatorassembly.SeeCOOLING
SYSTEM, Repair,Radiator
Ifair conditioning isfitted thecondenser will
have tobe removed, compressor pipesand
heater matrixhosesdisconnected.
SeeAIRCONDITIONING, Repair,Condenser
9.Remove rockercoverinsulation.
10.Remove feedpipe/hose fromturbo-charger and
intercooler.
11. Disconnect heaterhosesfromcylinder headand
heater rails.
12.Disconnect electricalfeedplugatrear ofcylinder
head.
13. Disconnect heaterplugfeed wire.