1999 LAND ROVER DEFENDER brake

10 - MAINTENANCE
CONTENTS
Page
MAINTENANCE
UNDERBONNET VIEW - Td5 1..............................................................................
SEATS AND SEAT BELTS 2..................................................................................
LAMPS, HORNS AND WARNING INDICATORS 2................................................
WIPERS AND WASHERS 3...................................................................................
HANDBRAKE 3.......................................................................................................
BATTERY CONDITION - Td5 4..............................................................................
HANDSET BATTERY 5...........................................................................................
HEADLAMP ALIGNMENT 5....................................................................................
ROAD WHEELS 6...................................................................................................
TYRE PRESSURES, CONDITION AND TREAD DEPTH 6....................................
BRAKE PADS, CALIPERS AND DISCS 7..............................................................
ROAD WHEEL SPEED SENSOR HARNESS - Td5 7............................................
FUEL FILTER ELEMENT 8.....................................................................................
FUEL FILTER SEDIMENTER - Td5 8.....................................................................
INTERCOOLER / COOLING SYSTEM 9................................................................
AMBIENT AIR PRESSURE (AAP) SENSOR - Td5 9..............................................
DOOR LOCKS AND HINGES 10............................................................................
ENGINE COOLANT 10...........................................................................................
BRAKE FLUID 11....................................................................................................
AIR FILTER ELEMENT AND DUMP VALVE 11.....................................................
AUXILIARY DRIVE BELT 12...................................................................................
PAS FLUID, CLUTCH FLUID AND SCREEN WASHER LEVELS 12.....................
STEERING BOX 13................................................................................................
ENGINE OIL 14.......................................................................................................
CENTRIFUGE ROTOR - Td5 14.............................................................................
FULL FLOW OIL FILTER 15...................................................................................
GEARBOX OIL 15...................................................................................................
TRANSFER BOX OIL 16.........................................................................................
FRONT AND REAR AXLE OIL 17..........................................................................
PROPELLER SHAFTS 18.......................................................................................
CLUTCH PIPES AND UNIONS 18..........................................................................
PAS PIPES AND UNIONS 19.................................................................................
ENGINE, GEARBOX, TRANSFER BOX AND AXLES 19.......................................
EXHAUST SYSTEM 20...........................................................................................
STEERING BOX AND SUSPENSION 20...............................................................
STEERING BALL JOINTS 21.................................................................................
SHOCK ABSORBERS 22.......................................................................................
TOWING BRACKET 22...........................................................................................
ENGINE AND TRANSMISSION MOUNTINGS 23..................................................
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MAINTENANCE
1
MAINTENANCE UNDERBONNET VIEW - Td5
LHD shown
1.Engine oil dipstick
2.Coolant expansion tank
3.Air cleaner
4.Brake/clutch fluid reservoir filler cap5.Windscreen washer reservior
6.Auxiliary drive belt
7.Engine oil filler cap
8.PAS fluid reservoir
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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.
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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.
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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.
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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.
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10MAINTENANCE
24
MAINTENANCE ENDORSE SERVICE RECORD
1.Insert date and mileage of next service.
2.Insert current mileage.
3.Tick one of the boxes on the brake fluid
replacement indicator.
4.Endorse service record with dealer stamp.
5.Sign and date the service record.
6.Sign and date the maintenance check sheet.REPORT ANY UNUSUAL FEATURES
1.Produce a written report detailing additional work
necessary, or items which may require attention
prior to the next service.
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EMISSION CONTROL
3
DESCRIPTION AND OPERATION 1.EGR Solenoid
2.Vacuum hose (light brown)
3.T-piece
4.Vacuum hose to brake servo
5.Non-return valve
6.Brake servo
7.Inlet manifold
8.Exhaust manifold
9.EGR pipe
10.Vacuum pump/alternator assembly
11.Air intake hose from intercooler
12.EGR valve assembly
13.Vacuum hose to vacuum pump
14.Vacuum hose to EGR valve suction port (blue)
15.To atmosphere
16.In-line filter
17.Vent hose - EGR solenoid to in-line filter (green)
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