Get Workshop maintenance Guide for Land Rover Defender 90 SUV First Generation (1990-2016)

123

SECTION 5

Workshop maintenance

Section Contents Page

Workshop maintenance 125...........................

Engine undertray 129.....................................

Engine oil renewal 132....................................

Engine oil filter renewal 133............................

Fuel filter renewal 134....................................

Fuel sedimenter cleaning 136.........................

Air cleaner element renewal 137.....................

Spark plug check/renewal 140........................

Ignition wiring & HT lead check 140...............

Distributor 141...............................................

Drive belts 142...............................................

Main gearbox oil renewal 150.........................

Transfer gearbox oil renewal 151....................

Axle oil renewal 152........................................

Brake pad/disc check 153...............................

Handbrake check/adjustment 154...................

Propeller shaft lubrication 154........................

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Workshop maintenance

125

WORKSHOP MAINTENANCE

This section covers workshop maintenance

for the V8 and Tdi engines only. Maintenance

of Td5 and 4-cylinder petrol models should be

referred to a qualified dealer.

It is recommended that the maintenance

procedures covered in this section of the

handbook, should only be carried out by

qualified personnel in a fully equipped

workshop; preferably an authorised Land

Rover dealer. However, if the vehicle is being

operated in a remote area, where full

workshop facilities are not available, some

maintenance can be carried out, provided that

it is completed in safe conditions by

experienced personnel.

WARNING

DO NOT carry out any maintenance in dusty,

damp or dirty conditions.

NOTE: Some of the servicing procedures

require specialised knowledge and equipment,

and therefore MUST be carried out by a

qualified person, familiar with the

maintenance and safety procedures practised

by Land Rover dealers. These NECESSARY

procedures are NOT covered in this handbook

and should be referred to a Land Rover dealer.

Servicing schedules

In normal operating conditions, servicing

should be carried out at intervals of 10,000

km (6,000 miles) or every six months,

whichever is sooner.

IMPORTANT INFORMATION

Special operating conditions

When a vehicle is operated in extremely

arduous conditions, or on dusty, wet or

muddy terrain, more frequent attention

must be paid to servicing requirements.

For example; if your vehicle experiences

deep wading conditions, even DAILY

servicing could be necessary to ensure

the continued safe and reliable operation

of the vehicle.

Contact a Land Rover dealer for advice.

Workshop maintenance

126

Emission control

Your vehicle is fitted with various items of

emission control equipment, designed to meet

specific territorial requirements.

You should be aware that unauthorised

replacement, modification or tampering with

this equipment by an owner or motor vehicle

repairer, may be unlawful and subject to legal

penalties.

In addition, engine settings must NOT be

tampered with. These have been established

to ensure that your vehicle complies with

stringent exhaust emission regulations.

Incorrect engine settings may adversely affect

exhaust emissions, engine performance and

fuel consumption, as well as causing high

temperatures, which will result in damage to

the catalytic converter (if fitted) and the

vehicle.

Replacement parts

It is essential that only Land Rover parts are

used, safety features embodied in the vehicle

may be impaired if other, non-approved parts

are used. In certain territories, legislation

prohibits the fitting of parts not to the

manufacturer’s specification.

WARNING

The fitting of parts of inferior quality, or the

carrying out of non-approved alterations or

conversions, may be dangerous and could

affect the safety of the vehicle and

occupants. It could also invalidate the terms

and conditions of the vehicle warranty.

Road testing on dynamometers

(’rolling roads’)

WARNING

Because your vehicle is equipped with

permanent four-wheel drive, it is essential

that any dynamometer testing is carried out

ONLY by a qualified person, familiar with

the dynamometer testing and safety

procedures practised by Land Rover

dealers. Contact your Land Rover dealer for

further information.

Workshop maintenance

127

SAFETY IN THE GARAGE

Whenever you carry out maintenance on

your vehicle, the following safety

precautions should be observed at all times.

• ALWAYS keep hands, tools and items of

clothing clear of all drive belts and pulleys

whilst they are in operation.

• DO NOT touch exhaust or cooling system

components until they are cool.

• DO NOT touch electrical leads or

components with the starter switch turned

on.

• NEVER leave the engine running in an

unventilated area; exhaust gases are

poisonous and contain carbon monoxide,

which can cause unconsciousness and

can be fatal.

• DO NOT work beneath the vehicle with the

lifting jack as the only means of support.

• Ensure sparks and naked lights are kept

away from the engine and battery

compartments.

• DO NOT use any lubricants, solvents or

sealants etc, without first reading any

warnings and instructions supplied with

these substances; they could be harmful if

improperly used.

WARNING

Remember, cooling fans and air

conditioning system condenser fans (if

fitted), may continue to operate after the

engine is switched off. Always wait until the

fans have completely stopped moving before

working in the engine compartment.

Fuel system safety

Fuel vapour is highly flammable and in

confined spaces, is also very explosive and

toxic. When fuel evaporates, it produces 150

times its own volume in vapour and when

mixed with air, becomes an easily ignitable

mixture; consequently even a small spillage is

very dangerous.

It is recommended that you always have a

FOAM, CO

GAS, or POWDER type fire

extinguisher close at hand when working with

fuel or the fuel system.

ALWAYS disconnect the battery negative lead

BEFORE carrying out work on the fuel system.

WARNING

Under no circumstances should any part of

the fuel system be dismantled or replaced

by anyone other than a suitably qualified

motor vehicle technician. Failure to comply

with this instruction may result in fuel

spillage with a consequent serious risk of

fire.

It is imperative that the battery is

disconnected BEFORE and not during any

work on the fuel system, as arcing at the

battery terminal could ignite fuel vapour in

the atmosphere.

Whenever fuel is being handled, transferred

or stored, or when carrying out work on the

fuel system, all forms of ignition MUST be

extinguished or removed, any lighting being

used MUST be flameproof and kept clear of

the fuel.

Workshop maintenance

128

Poisonous liquids

Most liquids and lubricants used in motor

vehicles are poisonous and should not be

consumed or brought into contact with open

wounds. These include; battery acid,

anti-freeze, brake, clutch and power steering

fluid, as well as petrol, diesel, engine oil and

windscreen washer additives.

For your own safety, ALWAYS read and obey

all instructions printed on labels and

containers.

Used engine oil

Prolonged contact with engine oil can cause

serious skin disorders, including dermatitis

and skin cancer. ALWAYS wash thoroughly

after contact.

It is illegal to pollute drains, water courses or

soil with toxic chemicals such as used engine

oil. ALWAYS dispose of vehicle liquids and

lubricants at authorised waste disposal sites,

or at garages which provide facilities for the

receipt of discharged batteries, used engine

oil and toxic chemicals. If in doubt, contact

your Local Authority for advice.

PROTECT THE ENVIRONMENT!

Workshop maintenance

129

ENGINE UNDERTRAY

Undertray removal

Front section:

The front undertray (1) can be removed to

gain access to the engine oil filter.

• Raise the vehicle on a ramp and position a

suitable support under the chassis front

crossmember.

• Lower the ramp slightly to improve

clearance between the axle and the

undertray.

• Remove the four bolts securing the

propellor shaft to the front axle and

reposition the shaft to prevent it from

fouling the undertray during removal.

• Remove the two bolts (2) securing the

undertray to the front crossmember.

• Remove the two nuts (3) securing the

undertray to the bump stop front fixing

bolts, on either side of the vehicle.

• Remove the two bolts (4) securing the

front and rear undertray together.

• Lower the undertray until it clears the

steering box and pull rearwards over the

axle to remove.

Refitting the undertray is the reverse of the

removal procedure, but take care to ensure

that the flanges of the undertray are properly

located in the rear undertray. Tighten the bolts

(2, 3 & 4) to a torque rating of 14 Nm

(10lbf/ft). Tighten the bolts securing the

propeller shaft to the front axle to a torque

rating of 47 Nm (35 lbf/ft).

Workshop maintenance

130

Undertray removal

Rear section:

The rear undertray (1) can be removed to

enable access to the gearbox drain and filler

level plugs.

• Raise the vehicle on a ramp.

• Remove the two bolts (2) securing the

rear and front undertray together.

• Remove the two bolts (3) securing the

rear undertray to the chassis

crossmember.

• Remove the bolt (4) securing the

undertray to the right hand side of the

chassis.

• Pull the undertray rearwards to disengage

from the front undertray and remove.

Refitting the undertray is the reverse of the

removal procedure, but take care to ensure

that the flanges of the front undertray are

properly located. Tighten the bolts (2, 3, & 4)

to a torque rating of 14 Nm (10 lbf/ft).

Workshop maintenance

131

UNDERTRAY ACCESS PANELS

Front:

The front access panel can be removed in

order to fit the engine timing cover wading

plug.

• Remove the five bolts securing the front

access panel to the undertray and

withdraw the panel.

• When refitting the access panel, tighten

the bolts to a torque rating of 14 Nm (10

lbf/ft).

Rear:

The rear access panel can be removed in

order to fit the flywheel housing wading

plug and to access the engine oil drain

plug.

• Rotate the panel anti-clockwise to

disengage the locking flanges, then

withdraw the panel from the undertray.

Workshop maintenance

132

ENGINE OIL RENEWAL (all engines)

NOTE: For engine oil check & top-up see

’Owner maintenance’.

WARNING

DO NOT attempt to drain the engine sump if

the engine has been running for some time,

the engine oil will be hot and may cause

severe scalding.

V8 engine

Tdi engine

NOTE: On some models, to access the engine

oil drain plug, it will be necessary to remove

the rear undertray access panel - see ’Engine

undertray’, earlier in this section.

With the vehicle resting on firm, level ground,

run the engine for a few minutes so that the

oil will drain more easily. Turn the starter

switch to position ’0’ and disconnect the

battery negative lead.

Remove the oil filler cap and position a

suitable container under the oil drain plug (4)

to collect the used oil.

Remove the drain plug and its washer and

allow the oil to drain completely.

NOTE: If, by necessity, this procedure is

being carried out in dusty or sandy

conditions, refit the drain plug as soon as the

main bulk of the oil has drained.

When the sump has fully drained, clean the

draining plug and the surrounding area of the

sump and refit with a new copper washer.

Refill the sump with fresh oil of the correct

specification (see ’General data’). Refit the

filler cap and let the vehicle stand for five

minutes to allow the oil to drain back into the

sump. Check the oil level using the dipstick

(as described in ’Owner maintenance’) and top

up until the correct level is obtained.

• DO NOT use oil previously drained from

the engine.

• DO NOT OVERFILL!

Workshop maintenance

133

V8 engines

Tdi engines

NOTE: On some models, to remove the oil

filter, it may be necessary to remove the front

engine undertray - see ’Engine undertray’,

earlier in this section.

ENGINE OIL FILTER RENEWAL

To prevent any possibility of air locks in the oil

pump, it is recommended that filter renewal is

carried out AFTER the engine oil has been

changed.

NOTE: On V8 engines, to minimise the risk of

draining the oil pump, ensure that the oil is at

the correct operating level before removing

the filter.

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Clean the area around the head of the

filter.

• Place a suitable container beneath the

filter.

• Using a strap wrench, unscrew the filter

(6) and discard it safely.

• Half fill the filter and smear the rubber

washer (7) of the new filter, with clean

engine oil of the correct specification (see

’General data’).

• Screw the filter on clockwise until the

rubber washer touches up against the

machined face, then tighten a further half

turn using hand pressure only. DO NOT

OVERTIGHTEN.

• Connect the battery negative lead and run

the engine at a fast idle for five minutes.

• Check the filter for leaks.

Stop the engine and let the vehicle stand for

five minutes to let the oil drain back into the

sump. Check the oil level (see ’Owner

maintenance’) and top up if necessary.

Workshop maintenance

134

FUEL FILTER RENEWAL

Petrol engines

Before carrying out any work on the fuel

system, it is essential that you have read and

understood the precautions listed at the

beginning of the section (see ’Fuel system

safety’).

The fuel filter is located next to the fuel pump

on the right hand side of the chassis (when

viewed from the rear).

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

NOTE: On 110 models the fuel filter is located

behind a protective cover (as illustrated

above). To remove the cover, unscrew the

three bolts (1).

• Unscrew the centre bolt (2) and withdraw

the filter bowl (3).

• Remove the small sealing ring (4) and

withdraw the element (8).

• Remove the large sealing ring (5) and

discard the old element.

• Clean the filter bowl with clean fuel, ensure

the centre and top sealing rings (7) are in

good condition. Replace if necessary.

• Fit the new element (small hole

downwards) and refit the small and large

sealing rings (4 and 5).

• Replace filter bowl and tighten the centre

bolt.

• Connect the battery negative lead.

• Start the engine and check for leaks.

Workshop maintenance

135

Tdi engine

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Clean the area around the filter head (1)

and place a container under the filter.

• Using a strap wrench, unscrew the filter

(2) and catch the fuel released in the

container.

• Wet the seal of the new filter (3) with

diesel fuel and screw the filter into

position and tighten.

• Ensure that the drain tap (4) at the base of

the filter is closed.

• Connect the battery negative lead.

• Start the engine and check for leaks.

Workshop maintenance

136

FUEL SEDIMENTER CLEANING

(Tdi engines)

NOTE: The fuel sedimenter should be drained

before removal; this process is covered in

’Owner maintenance’.

The fuel sedimenter is mounted on the

chassis rear side member, near the rear

wheel.

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Disconnect the fuel inlet pipe from the

sedimenter and raise the pipe above the

level of the fuel tank. The pipe must be

kept at this level to prevent the tank from

draining.

• Whilst supporting the sedimenter bowl

(1), unscrew the bolt on the top of the unit

(2) and then remove the bowl.

• Remove the sedimenter element (3) and

clean all parts with kerosene.

• Fit new seals (4) and re-assemble the

sedimenter unit.

• Slacken off the drain plug (5) until pure

diesel is emitted, then re-tighten.

• If necessary, prime the system.

• Connect the battery negative lead.

• Start the engine and check the sedimenter

for leaks.

Workshop maintenance

137

AIR CLEANER ELEMENT RENEWAL

V8 engine

Engine performance will be seriously

affected if the air cleaner element becomes

choked with dust and other airborne

particles.

• Unscrew the two retaining nuts (1).

• Disconnect the air cleaner hose (2).

• Remove the engine breather hose (3).

• Withdraw the air cleaner cannister (4).

• Unscrew the wing nut and washer (5).

• Remove the filter seal (6).

• Remove the element (7) from the

cannister.

• Discard the old element, DO NOT attempt

to clean it.

• Insert the new element and secure with

the wing nut and washer.

• Fit the air cleaner cannister.

• Fit the breather hose.

• Fit the air cleaner hose.

• Secure with the retaining straps and nuts.

NOTE: Check the dump valve (8) (see ’Air

cleaner dump valve check’).

Workshop maintenance

138

Tdi engine

Engine performance will be seriously

affected if the air cleaner element becomes

choked with dust and other airborne

particles.

• Release the two retaining clips (1).

• Raise the air cleaner slightly from its

cradle to improve access to the element.

• Unscrew the wing nut (2) and remove the

end cover.

• Unscrew the wing nut (3) and withdraw

the element.

• Clean the interior and exterior of the

casing and cover.

• Fit a new element, seal first, into the

casing.

• Secure the element with the wing nut.

• Fit the end cover and align the two arrows

(4).

• Position the air cleaner in its mounting

cradle and secure the two clips (1).

Workshop maintenance

139

Air cleaner dump valve check - all engines

The dump valve (8) is situated on the

underside of the element housing.

• Squeeze open the dump valve (as

illustration) and check that the interior is

clean. Renew the valve if perished.

Workshop maintenance

140

SPARK PLUG CHECK/RENEWAL

(petrol engines)

V8 engine

• Remove the HT leads from the spark

plugs.

• Remove the plugs using a spark plug

socket and ratchet.

• If they are in poor condition, replace with

new plugs of the correct specification (see

’General data’).

• Set the spark plug gaps to the correct

setting (see ’General data’).

• Fit the spark plugs and washers - DO NOT

OVERTIGHTEN.

NOTE: Fitting incorrect grades of spark plug,

may lead to piston overheating and engine

failure.

• Refit the HT leads in the correct order (as

illustration), ensuring that the leads are

firmly seated onto the plugs.

IGNITION WIRING & HT LEAD CHECK

Check the HT leads for insulation cracking, or

corrosion at end contacts. If the HT leads are

damaged, replace with new leads of the same

specification.

NOTE: Ensure leads are reconnected in the

correct order or the engine will misfire.

Workshop maintenance

141

DISTRIBUTOR

V8 engines

WARNING

ALWAYS disconnect the battery negative

lead before carrying out any maintenance on

the ignition and electrical systems.

The internal operating parts of the distributor

are protected by a plastic insulating cover (1)

and are pre-set during manufacture - they do

not require maintenance.

WARNING

DO NOT remove or tamper with the plastic

insulating cover.

• Clean the outer surfaces of the distributor

cap to remove dirt or grease.

• Unclip the cap and check it for cracks.

Clean the inside of the cap with a dry, lint

free cloth.

• Remove the rotor arm and check it for

wear - replace if necessary.

• Apply a spot of clean engine oil to the top

of the rotor spindle (2).

• Fit the rotor arm and distributor cap,

ensuring that they are properly located.

Secure the distributor cap with the two

clips.

Workshop maintenance

142

DRIVE BELTS

Driving belt tension

All pulleys and belts should be examined

regularly for any damage, deterioration or

fouling (grit, mud, oil etc). Replace or clean

where necessary.

After every off-road session, the drive belts

should be inspected for cuts and possible

damage caused by stones. If a belt has

jumped, reposition it correctly and, if

necessary, replace it at the earliest

opportunity.

WARNING

Before checking or adjusting any drive belt;

to prevent the possibility of serious injury,

disconnect the battery negative lead to

prevent the engine from being started.

DRIVE BELT - 300 Tdi engine

The 300 Tdi engine uses a ’serpentine’ type

drive belt, which drives all the ancillaries

except for the air conditioning compressor

and 24 Volt alternator (if fitted).

An automatic drive belt tensioner keeps the

belt at the correct tension, thereby eliminating

the need to manually check the belt deflection.

Under normal highway use, the belt must be

changed at 160,000 km (96,000 mile) or eight

year intervals (whichever occurs first), but

should be examined regularly for signs of

wear, splitting or oil contamination and

replaced accordingly.

Workshop maintenance

143

ALTERNATOR DRIVE BELT

V8 engine (without air-conditioning)

Check the belt deflection with thumb pressure,

mid-way between the alternator and

crankshaft pulleys. Movement should be

approximately 12 mm (0.5 in). If adjustment

is necessary;

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Loosen bolts (2).

• Loosen the adjustment bolts (3).

• Pivot the alternator away from, or towards

the engine, to increase, or reduce tension.

• Tighten the UPPER adjustment bolt (3).

• Tighten the LOWER adjustment bolt (3).

• Tighten both bolts (2).

• Connect the battery, run the engine for five

minutes at a fast idle and then switch off.

• Re-check belt tension.

V8 engine (with air-conditioning)

Check the belt deflection with thumb pressure,

mid-way between the steering pump and

alternator pulleys (arrowed (1) in illustration).

Movement should be between 4 and 6 mm

(0.16 and 0.25 in). If adjustment is necessary;

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Slacken the adjustment link clamp and

pivot bolts (2).

• Slacken the two alternator pivot bolts (3).

• Move the alternator towards, or away from

the engine to decrease, or increase

tension.

Workshop maintenance

144

WARNING

DO NOT use a lever to move the alternator.

ONLY apply hand pressure to the alternator

body when adjusting drive belt tension.

• Tighten the adjustment link clamp and

pivot bolts (2).

• Tighten the alternator pivot bolts (3).

• Connect the battery, run the engine for five

minutes at a fast idle and then switch off.

• Re-check belt tension.

Workshop maintenance

145

POWER STEERING PUMP DRIVE BELT

V8 engine

(without air-conditioning)

Check belt deflection with thumb pressure

mid-way between the crankshaft and steering

pump pulley. Movement should be between 4

and 6 mm (0.16 and 0.25 in). If adjustment is

necessary;

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Slacken the two pivot bolts (2).

• Slacken the pump adjustment clamp bolt

(3).

• Move the pump in the required direction to

obtain the correct tension.

WARNING

DO NOT lever, or apply pressure to the pump

body to tension the belt, as damage to the

pump may occur.

• Tighten adjustment clamp bolt (3).

• Tighten the two pivot bolts (2).

• Connect the battery, run the engine for five

minutes at a fast idle and then switch off.

• Re-check belt tension.

Workshop maintenance

146

POWER STEERING PUMP DRIVE BELT

V8 engine

(with air-conditioning)

Check the belt deflection with thumb pressure,

mid-way between the crankshaft and steering

pump pulleys. Movement should be between

4 and 6 mm (0.16 and 0.25 in). If adjustment

is necessary;

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Slacken the alternator adjustment link

clamp and pivot bolts (2) (see ’Alternator

drive belt - V8 engine with

air-conditioning’).

• Slacken the steering pump adjustment

clamp bolt (3).

• Slacken the two steering pump pivot bolts

(4).

• Move the steering pump in the required

direction to achieve the correct tension.

WARNING

DO NOT lever, or apply pressure to the pump

body to tension the belt, as damage to the

pump may occur.

• Tighten the pump adjustment clamp bolt

(3).

• Tighten the two pump pivot bolts (4).

• Adjust the alternator drive belt (see

’Alternator drive belt - V8 engine with

air-conditioning’).

• Connect the battery, run the engine for five

minutes at a fast idle and then switch off.

• Re-check both steering pump and

alternator belt tension.

Workshop maintenance

147

AIR CONDITIONING COMPRESSOR

DRIVE BELT

Tdi engine

Correct belt tension an only be achieved using

a suitably calibrated torque meter.

• Slacken the 3 bolts (1) securing the

tensioner.

• Apply a clockwise torque of 35 Nm to the

square drive (2) of the tensioner and

tighten the bolts to 25 Nm.

Workshop maintenance

148

AIR CONDITIONING COMPRESSOR

DRIVE BELT

V8 engine

Check the belt deflection with thumb pressure,

mid-way between the compressor and

fan/water pump pulley. Movement should be

approximately 4 mm to 6 mm (0.16 to 0.25

in). If adjustment is necessary;

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Slacken the two compressor mounting

bracket clamp bolts (3).

• Slacken the pivot bolt (4) in the centre of

the bracket.

• Move the compressor towards/away from

the engine, to decrease/increase the

tension as required.

WARNING

DO NOT lever, or apply pressure to the

compressor, as this could cause permanent

damage.

• Tighten the clamp bolts (3).

• Tighten the pivot bolt (4).

• Check tension.

• Connect the battery, run the engine for five

minutes at a fast idle and then switch off.

• Re-check the belt tension.

Workshop maintenance

149

FAN BELT

V8 engine (with air conditioning)

On vehicles fitted with air conditioning, a

tensioner pulley is fitted. Check the belt

deflection with thumb pressure, mid-way

between the fan and crankshaft pulleys, on the

side opposite the tensioner pulley. Movement

should be approximately 4 mm to 6 mm (0.16

to 0.25 in). If adjustment is necessary;

• Turn the starter switch to position ’0’ and

disconnect the battery negative lead.

• Slacken the tensioner pulley pinch bolt (2).

• Move the pulley to the left/right to

increase/decrease tension.

• Tighten the pulley pinch bolt.

• Connect the battery, run the engine for five

minutes at a fast idle and then switch off.

• Re-check the belt tension.

Workshop maintenance

150

MAIN GEARBOX OIL RENEWAL

WARNING

For safety, DO NOT work underneath the

vehicle unless it is safely parked with the

wheels chocked, or is supported by heavy

duty stands.

Extreme care should be taken when draining

gearbox oil, it may be hot and cause severe

scalding.

Ensure the vehicle is parked on firm, level

ground and chock the wheels. Place a suitable

container under the gearbox to catch the used

oil.

NOTE: On some models, to access the main

gearbox drain and fill plugs, it will be

necessary to remove the rear section of the

engine undertray - see ’Engine undertray’,

earlier in this section.

• Clean the area surrounding the drain plug

(2) and filler level plug (3), to prevent

contamination of the gearbox.

• Remove the drain plug (2) and allow the

oil to drain completely.

• Clean and refit the drain plug.

• Remove the filler level plug (3) and inject

the correct grade of oil (see ’General data’)

until it begins to run from the hole.

WARNING

Use only NEW oil - DO NOT use oil

previously drained from the system.

• Clean and refit the filler level plug.

• Wipe any surplus oil from the area and

remove the wheel chocks.

Workshop maintenance

151

TRANSFER GEARBOX OIL RENEWAL

WARNING

For safety, DO NOT work underneath the

vehicle unless it is safely parked with the

wheels chocked, or is supported by heavy

duty stands.

Extreme care should be taken when draining

gearbox oil, it may be hot and cause severe

scalding.

Ensure the vehicle is parked on firm, level

ground and chock the wheels. Place a suitable

container under the gearbox to catch the used

oil.

• Clean the area surrounding the drain plug

(2) and filler level (3) plug, to prevent

contamination of the gearbox.

• Remove the drain plug (2) and allow the

oil to drain completely.

• Clean and refit the plug with a new

washer.

• Remove the filler level plug (3) and inject

the correct grade of oil (see ’General data’)

until it begins to run from the hole.

WARNING

Use only NEW oil - DO NOT use oil

previously drained from the system.

• Clean and refit the filler level plug.

• Wipe any surplus oil from the area and

remove the wheel chocks.

Workshop maintenance

152

FRONT/REAR AXLE OIL RENEWAL

WARNING

For safety, DO NOT work underneath the

vehicle unless it is safely parked with the

wheels chocked, or is supported by heavy

duty stands.

Extreme care should be taken when draining

axle oil, it may be hot and cause severe

scalding.

NOTE: A front axle is illustrated, but the

procedure is the same for both axles.

Ensure the vehicle is parked on firm, level

ground and chock the wheels. Place a suitable

container under the axle to be drained to catch

the used oil.

• Clean the area surrounding the drain plug

(2) and filler level plug (3), to prevent

contamination of the axles.

• Remove the drain plug (2) and allow the

oil to drain completely.

• Clean and refit the drain plug.

• Remove the filler level plug (3) and inject

the correct grade of oil (see ’General data’)

until it begins to run from the hole.

WARNING

Use only NEW oil - DO NOT use oil

previously drained from the system.

• Clean and refit the filler level plug.

• Wipe any surplus oil from the area and

remove the wheel chocks.

Workshop maintenance

153

BRAKE PAD, DISC AND CALIPER CHECK

If the vehicle is being operated in arduous

conditions, especially when deep mud and/or

wading situations are regularly encountered,

the condition of the brake pads, discs and

calipers should be checked at least weekly, if

not even more frequently.

Hydraulic disc brakes are fitted to the front

and rear wheels, they are self adjusting and

therefore, no provision for manual adjustment

is made.

• Check the thickness of the brake pads,

which should not be less than 3mm

(0.125 in).

• Check for uneven brake pad wear.

• Check for oil contamination on the brake

discs and pads.

• Check condition of the brake discs for

wear and/or corrosion.

• Check the brake calipers for any leaking

brake fluid.

If necessary, any replacement or rectification

of discs, brakes or calipers, should be carried

out by a qualified dealer.

Workshop maintenance

154

HANDBRAKE CHECK/ADJUSTMENT

WARNING

For safety, DO NOT work underneath the

vehicle unless it is safely parked with the

wheels chocked, or is supported by heavy

duty stands.

Ensure the vehicle is parked on firm, level

ground and chock the wheels.

If the parking brake movement is excessive,

adjust as follows:

• Raise one rear wheel clear of the ground

and ensure it is supported securely with

an axle stand.

• Release the handbrake.

• Tighten the adjusting bolt (3) until brake

drum will not rotate (by hand).

• Further tighten the adjusting bolt to a

torque of 25 Nm (18 lbf/ft) to ensure that

the brake drum is locked - if this is not the

case, consult a Land Rover dealer.

• Finally, slacken the adjusting bolt by

turning it 1.5 turns anti-clockwise.

The brake drum should now be free to rotate,

and the brakes shoes correctly adjusted.

PROPELLER SHAFT LUBRICATION

• Clean all the grease nipples on the front

and rear propshaft universal joints (1).

Charge a low pressure hand grease gun

with the recommended grade of grease

(see ’General data’) and apply to the

grease nipples (2).

WARNING

Any additional greasing of the propshaft

MUST be carried out by a qualified dealer.

Workshop maintenance for Your Land Rover Defender 90 SUV First Generation (1990-2016)

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