1996 LAND ROVER DEFENDER maintenance

10MAINTENANCE
2
MAINTENANCE BATTERY CONNECTIONS
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See
ELECTRICAL, Repair, Battery
Disconnect battery leads, clean and grease with
petroleum jelly, including battery terminals.
CHECK OPERATION OF DOOR SWITCHES
When a Vehicle Immobilisation and Alarm System is
fitted it is important that all door and bonnet switches
operate correctly, otherwise perimeter and interior
protection may not function if a door or the bonnet is
opened.VEHICLE EXTERIOR
CHECK/ADJUST HEADLAMP ALIGNMENT
Check/adjust headlamp alignment.
CHECK ROAD WHEELS AND TYRES
Check road wheels for damage.
Check tyres, including spare, for compliance with
manufacture's specificaton.
Check visually for cuts, lumps, bulges, uneven tread
wear and tread depth.
See INTRODUCTION,
Information, wheels and tyres
Check/adjust tyre pressures.See WHEELS AND
TYRES, Repair, Tyres pressures
INSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND CONDITION OF DISCS
Check thickness of brake pads, and renew if thickness
is less than 3,00 mm (0.12 in). Check brake pads for
oil contamination and fit a new set, if necessary,
See
BRAKES, Repair, front brake pads
orSee
BRAKES, Repair, rear brake pads
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads as complete axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to carry
out this operation.
See STEERING, Adjustment,
front wheel alignment
CHECK OPERATION OF ALL DOORS/TAILGATE,
BONNET AND LOCKS
LUBRICATE ALL DOOR/TAILGATE HINGES, AND
DOOR CHECK/LOCK MECHANISMS

MAINTENANCE
3
MAINTENANCE UNDER BONNET MAINTENANCE
UNDER BONNET COMPONENTS
A - RH drive
1.Brake fluid reservoir
2.Clutch fluid reservoir
3.Air cleaner element
4.Engine breather filter
5.Oil filler cap
6.Oil level dipstick
7.Heater/air conditioning unit
8.Windscreen washer reservoir
9.Power steering pump reservoir10.Intercooler and hoses
11.Radiator filler plug
12.Radiator
13.Oil cooler
14.Fuel filter
15.Accelerator linkage
16.Expansion tank
17.Air cleaner dump valve

10MAINTENANCE
4
MAINTENANCE
UNDER BONNET COMPONENTS
B - LH drive
1.Brake fluid reservoir
2.Clutch fluid reservoir
3.Air cleaner element
4.Engine breather filter
5.Oil filler cap
6.Oil level dipstick
7.Heater/air conditioning unit
8.Windscreen washer reservoir
9.Power steering pump reservoir10.Intercooler and hoses
11.Radiator filler plug
12.Radiator
13.Oil cooler
14.Fuel filter
15.Accelerator linkage
16.Expansion tank
17.Air cleaner dump valve

MAINTENANCE
5
MAINTENANCE REV: 05/99 CHECK COOLING, INTERCOOLING AND HEATING
SYSTEMS
Check cooling, and heater systems for leaks and
pipes/hoses for security and condition. Refill or top up
as necessary.
CAUTION: It is important that the correct
procedure is followed when refilling or
topping up the cooling system to avoid
trapping air in the system.
WARNING: Do not remove caps and plugs
when engine is hot because cooling
system is pressurised and personal
scalding could result.
1.Remove plastic plugs from thermostat housing
and radiator.
2.Fill cooling system with correct concentration
and specification of anti-freeze.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
3.Fill from expansion tank until radiator is full, with
level in expansion tank the same as in radiator.
NOTE: Care should be taken to avoid
excess coolant spillage from radiator.
4.Fit plastic plug in radiator.
5.Add a further 1 litre (1.76 pints) of coolant to
expansion tank and allow to settle.
6.Refit expansion tank cap and thermostat
housing plug.
7.Run engine at idle speed for five minutes.
8.Switch off engine, check that expansion tank
coolant is level with top of indicator post and top
up as necessary.Check intercooler and turbo-charger system for air
leaks and pipes/hoses for security and condition.
All system hoses should be renewed at first signs of
deterioration.
VALVE CLEARANCES - CHECK/ADJUST
Check/adjust valve clearances.
See ENGINE ,
Adjustment, Valve clearances - check and adjust
RENEW FUEL FILTER ELEMENT
Remove
1.Clean area around filter head and position a
container beneath.
2.Unscrew and remove filter, catch fuel released.
Refit
3.Wet seal of new filter with fuel.
4.Screw new filter into position.
5.Ensure drain tap is fully closed.

10MAINTENANCE
6
MAINTENANCE RENEW AIR CLEANER ELEMENT AND CLEAN
DUMP VALVE
Remove
1.Release 2 retaining clips and lift air cleaner from
its cradle sufficiently to gain access to element.
2.Unscrew wing nut and remove end cover.
3.Unscrew second wing nut and withdraw element
from air cleaner casing.
4.Clean interior and exterior of casing and cover.
5.Squeeze open dump valve and check that
interior is clean. Renew valve, if perished.Refit
6.Fit new element, seal first, into casing and
secure with wing nut.
7.Fit end cover, align mating arrows, and secure
with wing nut.
8.Position air cleaner in mounting cradle and
secure with retaining clips.
CLEAN ENGINE BREATHER FILTER
Remove
1.Disconnect breather top hose.
2.Remove single bolt and ease breather from
rocker cover.
3.Disconnect bottom hose and remove engine
breather.
4.Using suitable flushing solvent, thoroughly clean
breather filter. Remove and discard rubber 'O'
ring from breather pipe.
Refit
5.Fit new rubber 'O' ring to engine breather.
6.Connect breather bottom hose.
7.Locate breather into rocker cover and secure
with retaining bolt, tightening to
9 Nm (7 lbf/ft).
8.Connect breather top hose.

MAINTENANCE
7
MAINTENANCE RENEW AUXILIARY DRIVE BELT
Renew drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
RENEW COMPRESSOR DRIVE BELT
Renew compressor drive belt.
See AIR
CONDITIONING, Repair, Compressor drive belt
CHECK/TOP UP POWER STEERING RESERVOIR
WARNING: DO NOT start engine if fluid
level in reservoir has dropped below
dipstick - severe damage to the power
steering system could result.
NOTE: Check fluid level with engine
switched off and system cold. Ensure that
steering wheel is not turned after stopping
engine.
1.Clean and remove reservoir cap.
2.Wipe distick clean and fully refit cap.
3.Remove cap and check fluid level. Ensure fluid
level is between UPPER mark and end of
dipstick.
4.Top up, if necessary, with recommended fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
DO NOT fill above
UPPER mark on dipstick.CHECK/TOP UP CLUTCH FLUID RESERVOIR
WARNING: Clutch fluid will damage
painted surfaces; clean up any spillage
immediately and rinse with plenty of water.
If clutch fluid should come into contact with the
skin or eyes, rinse immediately with plenty of
water.
1.Clean and remove reservoir cap.
2.Check fluid level and top up if necessary,
maintaining the level approximately 10 mm (0.39
in) below top of reservoir, using recommended
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids

10MAINTENANCE
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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.