1996 LAND ROVER DEFENDER engine

MAINTENANCE
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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
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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
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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.

MAINTENANCE
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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
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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.