LAND ROVER DEFENDER 1999 Repair Manual

10MAINTENANCE
2
MAINTENANCE SEATS AND SEAT BELTS
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return under
its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure. Release
seat belt buckle and check for correct operation.
9.Check tightness of accessible seat belt
mountingsLAMPS, HORNS AND WARNING INDICATORS
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of brake
lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
ProCarManuals.com

MAINTENANCE
3
MAINTENANCE WIPERS AND WASHERS
1.Operate screen washer and switch on wipers.
Check washer jets are correctly aimed and
check for smooth smearless operation across
screen of wiper blades at all speeds, including
intermittent.
2.Repeat operation for rear screen
wipers/washers.
3.Check all wiper blades for condition and signs of
splits or damage.
4.Check security of wiper arms.HANDBRAKE
1.With the vehicle stationary, apply handbrake and
check for correct operation.See BRAKES,
Adjustment.
2.Release handbrake and check for correct
operation.
NOTE: Any adjustment required as a result
of the checking process will be subject to
additional labour and/or material cost and
should not be carried out without the
authorisation of the customer.
Adjust handbrake (First 12,000 miles/12 months
only
1.Adjust handbrake cable.See BRAKES,
Adjustment.
NOTE: Additional time is built into the first
12,000/12 months service time to allow for
handbrake cable adjustment.
ProCarManuals.com

10MAINTENANCE
4
MAINTENANCE BATTERY CONDITION - Td5
Remove
1.Remove drivers seat base.
2.Release clip securing battery cover.
3.Remove battery cover.
NOTE: The vehicle may be fitted with an
alarm and immobilisation system. To
prevent the alarm from sounding, it is
important that the following procedure is used
when disconnecting the battery.
4.Turn the ignition switch to position’II’, and then
to position’0’.
5.Remove the ignition key.
6.Disconnect the vehicle -ve terminal within 15
seconds.
NOTE: Always disconnect the -ve terminal
first. When replacing, connect the +ve
terminal first.
Check
The battery fitted to Td5 models is designed to be
maintenance free, so topping-up is not possible. On
the top of the battery is a battery indicator. When the
indicator shows:
GREEN - The battery is in a good state of charge.
DARK (turning to black) - The battery needs
charging.
CLEAR (or light yellow) - The battery needs
replacing. Do not charge the battery or jump start
the vehicle in this condition.
If the green dot is missing, the battery needs
charging.
NOTE: If the indicator shows clear or
yellow, tap the indicator with the handle of
a screwdriver to disperse any air bubbles.
If the indicator colour remains unchanged, the
battery will need replacing.
Refit
7.Clean and grease battery terminals and leads
with petroleum jelly.
8.Connect leads to battery (+ve first) and tighten
clamp bolts.
9.Fit battery cover and secure with clip.
10.Fit drivers seat base.
ProCarManuals.com

MAINTENANCE
5
MAINTENANCE HANDSET BATTERY
Remove
NOTE: Do not remove a battery until you
are ready to install the replacement.
Always fit a Land Rover STC4080 or a
Panasonic CR2032 replacement battery.
1.Unlock the vehicle and disarm the alarm system.
2.Turn the ignition switch to position’II’, then turn
to position’0’and remove the key.
3.Carefully prise the handset apart, starting from
the keyring end. Avoid damaging the seal
between the two halves of the case.
CAUTION: Do not allow moisture to get
inside the handset.
4.Slide the battery out of its clip, taking care to
avoid touching the circuit board or the contact
surfaces of the clip.
5.Press and hold one of the buttons for at least 5
seconds to drain any residual power from the
handset.
Refit
6.Fit the new battery, ensuring that correct polarity
is maintained (+ve side facing up). Finger marks
will adversely affect battery life. Avoid touching
the flat surfaces of the battery, and wipe clean
before fitment.
7.Reassemble the two halves of the handset.
Operate the Padlock symbol button at least 4
times within range of the vehicle to
resynchronise the hanset.HEADLAMP ALIGNMENT
1.Check alignment of headlamps.See
ELECTRICAL, Adjustment.
ProCarManuals.com

10MAINTENANCE
6
MAINTENANCE ROAD WHEELS
Remove
1.Loosen wheel nuts. Raise vehicle for wheel free
condition and remove the wheel nuts.
2.Mark the wheel to stud relationship to ensure
that the wheels are refitted in the same
orientation.
Refit
3.Apply a thin coat of anti-seize compound to
wheel hub centre.
4.Refit wheels to original hub position.
NOTE: When refitting road wheel nuts do
not overtighten using powered tools.
Ensure the wheel nuts are correctly
torqued in the correct sequence.
5.Tighten wheel nuts.
Steel wheels -100 Nm (80 lbf/ft)
Alloy wheels -130 Nm (96 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)TYRE PRESSURES, CONDITION AND TREAD
DEPTH
1.Check for any apparent damage to tyres, paying
particular attention to side walls.
2.Look at tyre treads and check for any unusual
wear patterns which may indicate out of
specification adjustment of steering or
suspension.
NOTE: Any adjustments to steering or
suspension will be subject to additional
labour and/or material cost and should not
be carried out without the authorisation of the
customer.
3.Measure the tread depth across the width of the
tyre and around the circumference. Annotate the
maintenance check sheet with the lowest figure
obtained from each tyre.
NOTE: Any requirement to replace tyres
should be advised to the customer before
any remedial work is carried out. This will
be subject to additional labour and/or material
cost and should not be carried out without the
authorisation of the customer.
ProCarManuals.com

MAINTENANCE
7
MAINTENANCE BRAKE PADS, CALIPERS AND DISCS
1.With front road wheels removed, check brake
pad thickness and ensure that both pads are
wearing evenly.
2.Check brake discs for signs of cracking,
excessive scoring or oil contamination.
NOTE: Any requirement to replace brake
pads or brake disc 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.
3.Check for any signs of brake fluid leakage from
caliper seals, hoses or unions.
4.Using brake cleaner, remove excessive deposits
of brake dust from pads, calipers and disc
shields.ROAD WHEEL SPEED SENSOR HARNESS - Td5
1.Check each sensor harness is correctly and
securely routed.
2.Inspect each harness for chafing or damage.
NOTE: Any requirement to replace a road
wheel speed sensor 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.
ProCarManuals.com

10MAINTENANCE
8
MAINTENANCE FUEL FILTER ELEMENT
1.Renew fuel filter element.See FUEL SYSTEM,
Repair.FUEL FILTER SEDIMENTER - Td5
WARNING: Fuel vapour is highly
flammable and in contained speces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR
POWDER close at hand when handling or draining
fuel.
1.Disconnect battery negative lead.
2.Position suitable container beneath fuel filter
3.Disconnect multiplug from sedimenter
4.Rotate sedimenter anti-clockwise until water
flows from drain tube.
5.Allow to drain until diesel fuel flows from drain
tube.
6.Rotate sedimenter fully clockwise.
7.Connect multiplug.
8.Reconnect battery negative lead.
ProCarManuals.com

MAINTENANCE
9
MAINTENANCE INTERCOOLER / COOLING SYSTEM
1.Visually check for any obstructions in the
radiator and intercooler matrix and remove
debris as necessary.
2.Visually check fan blades for damage.
3.Check cooling, intercooler and heating systems
for leaks, hoses and oil pipes for security and
condition.
4.Check accessible hose clips for tightness.
5.Check coolant level, top-up if necessary
Cooling System Top-Up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.
3.Fit expansion tank filler cap.
Intercooler Flush
1.Remove intercooler.See FUEL SYSTEM,
Repair.
2.Flush intercooler element using Unicorn
Chemicals’C’Solve following the manufaturers
instructions.
3.Thoroughly dry intercooler ensuring that no trace
of solvent remains in the element.
4.Refit intercooler.See FUEL SYSTEM, Repair.AMBIENT AIR PRESSURE (AAP) SENSOR - Td5
1.Check ambient air pressure sensor for damage.
ProCarManuals.com

10MAINTENANCE
10
MAINTENANCE DOOR LOCKS AND HINGES
Front, rear and tail doors
1.Open each door in turn and lubricate door
hinges and check strap using recommended
lubricant.
2.Lubricate door lock, striker and private lock using
PTFE lubricant. Remove excessive lubricant,
particularly from door striker area, to avoid
customer complaint.
3.Check tightness of accessible door lock and
striker fixings
4.Open and close door to check for smooth,
noise-free operation. Ensure door closes
securely.
5.Check for smooth operation of private lock.
Bonnet
1.With bonnet open, lubricate hinges, striker, lock
and safety catch using a suitable lubricant.ENGINE COOLANT
1.Renew engine coolant.See COOLING
SYSTEM, Adjustment.
ProCarManuals.com

MAINTENANCE
11
MAINTENANCE BRAKE FLUID
1.Renew brake fluid.See BRAKES,
Adjustment.AIR FILTER ELEMENT AND DUMP VALVE
1.Replace air cleaner element.See FUEL
SYSTEM, Repair.
2.Remove all dirt from dump valve.
ProCarManuals.com