maintenance LAND ROVER DEFENDER 1999 Owner's Manual

10MAINTENANCE
14
MAINTENANCE ENGINE OIL
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Position suitable container beneath sump.
3.Clean arear around drain plug.
4.Remove oil drain plug, discard sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit engine drain plug and tighten to23 Nm (17
lbf.ft).
8.Fill engine with recommended grade of oil to
correct mark on dipstick.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
9.Fit underbelly panel.See CHASSIS AND
BODY, Repair.CENTRIFUGE ROTOR - Td5
1.Renew centrifuge rotor.See ENGINE , Repair.
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MAINTENANCE
15
MAINTENANCE FULL FLOW OIL FILTER
1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
WARNING: Avoid excessive skin contact
with used gearbox oil. Used gearbox oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Renew gearbox oil.See MANUAL GEARBOX,
Adjustment.
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10MAINTENANCE
16
MAINTENANCE TRANSFER BOX OIL
WARNING: Avoid excessive skin contact
with mineral oil. Mineral oils remove the
natural fats from the skin, leading to
dryness, irritation and dermatitis.
Check
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Remove all traces of sealant from threads of oil
filler/level plug.
6.Apply Loctite 290 to threads of oil filler/level plug
and tighten to25 Nm (18 lbf.ft).
7.Remove all traces of oil from main casing.
8.Fit underbelly panel.See CHASSIS AND
BODY, Repair.Renew
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Place a suitable container beneath transfer box
to catch any fluid spillage.
3.Clean area around oil filler/level and drain plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug.
6.Allow oil to drain.
7.Apply Loctite 290 to threads of oil drain plug.
8.Fit transfer box drain plug and tighten to30 Nm
(22 lbf.ft).
9.Fill transfer box with recommended oil to bottom
of oil filler/level plug hole.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
10.Remove all traces of sealant from threads of oil
filler/level plug.
11.Apply Loctite 290 to threads of oil filler/level plug
and tighten to25 Nm (18 lbf.ft).
12.Remove all traces of oil from main casing.
13.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
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MAINTENANCE
17
MAINTENANCE FRONT AND REAR AXLE OIL
Renew
A- Front and rear axle, 90 models, front, 110/130
models.
B- Rear axle, 110/130 models.
WARNING: Avoid excessive skin contact
with used axle oil. Used axle oil contains
potentially harmful contaminants which
may cause skin cancer or other serious skin
disorders.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.
4.Inject new oil, until it runs out from filler/level
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
5.Clean and refit filler/level plug.
Check
1.Ensure vehicle is level.
2.Using 13 mm square drive wrench, remove
filler/level plug.
3.If necessary inject new oiluntil oil runs out from
filler/level hole. Allow excess oil to drain and
wipe clean.See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
4.Clean and refit filler/level plug.
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10MAINTENANCE
18
MAINTENANCE PROPELLER SHAFTS
1.Clean area around front universal joint grease
nipple.
2.Apply recommended grease to the grease
nipple.See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.CLUTCH PIPES AND UNIONS
Check
1.Check route of clutch pipe from master cylinder
to slave cylinder. Ensure that pipe is correctly
retained and shows no signs of fluid leakage or
chafing.
2.Check unions for signs of fluid leakage.
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MAINTENANCE
19
MAINTENANCE PAS PIPES AND UNIONS
Check
1.Check PAS pipes for correct, secure routing and
signs of chafing.
2.Check for signs of fluid leakage from PAS pump,
hoses, and hose unions.ENGINE, GEARBOX, TRANSFER BOX AND AXLES
Check
1.Check for oil leaks from engine, gearbox, tansfer
box, and front and rear axles. Pay particular
attention to areas around oil seals.
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10MAINTENANCE
20
MAINTENANCE EXHAUST SYSTEM
1.Visually check condition of exhaust system for
signs of damage.
2.Check condition of exhaust heat shields.
3.Check exhaust system is firmly secured and
check condition of exhaust mounting rubbers,
clamps and brackets.STEERING BOX AND SUSPENSION
1.Check steering box fixings. Tighten if necessary
to81 Nm (60 lbf.ft).
2.Check LH and RH front radius arm fixings.
Tighten if necessary.See FRONT
SUSPENSION, Repair.
3.Check Panhard rod fixings. Tighten if necessary.
See FRONT SUSPENSION, Repair.
4.Check all rear axle fixings. Tighten if necessary.
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MAINTENANCE
21
MAINTENANCE STEERING BALL JOINTS
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent, fit a new joint assembly.
2.Check condition of steering ball joints paying
particular attention to dust covers.
NOTE: Any requirement to replace the
steering ball joints should be advised to
the customer as this will incur additional
labour and/or material cost and should not be
carried out without the authorisation of the
customer.
NOTE: Ball 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.
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10MAINTENANCE
22
MAINTENANCE SHOCK ABSORBERS
1.Check for signs of leakage from suspension
dampers.
2.Check for signs of suspension damper damage.TOWING BRACKET
1.Check security of towing bracket.
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MAINTENANCE
23
MAINTENANCE ENGINE AND TRANSMISSION MOUNTINGS
1.Check condition of front LH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
2.Check condition of front RH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
3.Check condition of rear LH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
4.Check condition of rear RH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.ROAD TEST
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as layed
down by dealership processes. Secondly, for a skilled
technician to assess the general condition of the
vehicle and report any conditions that the customer
should be made aware of.
CAUTION: Two wheel roller tests must not
be carried out. Four wheel roller tests
must be restricted to 3 mph (5 kph).
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
2.With vehicle stationary, turn steering from lock to
lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
3.Depress clutch and select all gears in turn.
Check for smooth notch free engagement.
4.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
Engine noise
Gearbox noise
Suspension noise
Body noise
Braking system operation
Gear selection
Engine performance
5.Check for correct operation of all instruments
and warning devices where practical.
6.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
7.Check all underbonnet fluid levels and top-up if
necessary.
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