LAND ROVER DEFENDER 1996 Repair Manual

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.