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Land Rover Defender 90 110 Workshop Book 1 Rover

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    							Lubrication nipples 
    (hubs, ball joints, 
    etc.) ~~. ., - ßP Castrol  Duckhams  Esso  Mobil- Fina  Shell Marfak Energrease LM Grease LU 10 Multi- grease  MP  Marson Ketinax A All purpose L2 pumosc HTL 2 Grease 
    Cooling system 
    Anti
    -freeze  Universal Anti-freeze 
    See  under  Anti-freeze  section 09. 
    RECOMMENDED LUBRICANTS  AND FLUIDS 
    Service instructions for temperate climates - ambient temperature range -10°C to 35°C 
    COMPONENTS BP I CASTROL PETROFINA I SHELL I TEXACÖ~ DUCKHAiMS 
    Duckhams 15W/S0 Hypergrade 
    Motor  Oil 
    ESSO MOBIL 
    Engine  V8 
    Carburetter 
    Dashpots 
    Fina  Shell Super Havoline 
    Supergradc Motor Oil Motor Oil 
    Motor  Oil 15W/40 or 15W/40 or 10W/40 or IOW140 Eurotex  HD 15W/40 10WBO 
    (15W/50) or 
    Superlube  Super (15W/40) 10W/40 or Kally Formula 15W/50 Nova llOW/40 1 
    Duckhams 15W/SO Hypergrade 
    Motor Oil  Esso 
    1 Mobil 1 Fina 1 Shell Super Superlube 
    Super Supergrade  Motor Oil (15W/40) 10W/40or MotorOil 15W/40 or Mobil 1 Rally 1OW/40 or low140 Formula 15W140 
    Havoline 
    Motor Oil 
    i15W/40 1 
    Engine 
    4-cyl. pctrol 
    15W/40 Shell  Super 
    Supergrade  Motor  Oil 
    1 OW/40 or Super 15W/40 RimulaX  plus 1 15Wi40 or 
    Engine 
    4-cyl.  diesel  Duckhams 15w/50 Hypergrade 
    Motor  Oil or Duckhams Fleetol Multi-V 20Wi50 or Duckhams 
    Fleet Master 
    15w/40 
    Duckhams 
    Q-Matic 
    or Mobil 1 Eurotex 
    Rally  Motor Oil 
    Formula 
    town0 
    Tvoe G 
    LT77-five- speed  gearbox 
    LT95 - four- speedgearbox 
    including  transfer 
    box 
    Front  differential 
    Rear  differential 
    jwivel pin iousings and -R30R & LT23OT rransfer box 2T85 -five- ,peed gearbox - /8 cylinder  Duckhams 
    15W/50 Esso 
    Mobil  Fina 
    Shell Super Havoline 
    Superlube  Super  Supergrade 
    Motor Oil Motor Oil (15W140) IOW140 Motor Oil 15W/40 or 1SW140 or 10W/40 or 1 OW/40 Eurotex HD 15w/40 IOW/30 Esso  Mobil  Fina  Shell Texaco 
    Hypergrade 
    Motor 
    Oil 
    Duckhams 
    Hypoid 
    90 
    Gear Oil  Mobilube  Pontonic  MP Multigear 
    GX 1 HDW ISAEXOW/90 I Lubricant 35w/90 EP 85W190 I 3ils lisled on lines marked (*) may 
    transfer box. so be used in LTZ! 
    3P Visco !Ooo 15W/40) or 3P Visco (ova 10W/40) 
    mergrease -2 
    %P Gear Oil #AB 90EP 
    !P 
    Castrol 
    GTX 
    (15W/50) 
    Duckhams  Esso Mobil Fina  Shell 
    Hypergrade  Superlube 
    Super  Supergrade Super Multigrade 15W/50 15W/40 10w/40 Motor Oil 10W/40 or 15w/40 15W/40 or 10W/40 
    Havoline Motor Oil 15 W/40 or Eurotex HD 10W/30 
    Marfak 
    All purposc Grease 
    Texaco 
    Multigear 
    Lubricant 
    EP 85W/90 Texamatic 
    Fluid 9226 
    Duckhams  Esso  Mobil- LB 10 I Multi- Castrol LM Grease :rant and rear 
    lteering box 
    Manual) 
    I purposc I- I I Grease I I I Duckhams  Esso  Mobil  Fina  Shell 
    Hypoid 90 Gear Oil Mobilube  Pontonic  MP 1 s5w/90 GX 1 HD9U /SAESOW/9O 1%;; 
    Castrol HYPOY SAE 90EP 
    Castrol 
    TO Dexron  IID Duckhams 1 Y;; 1 Mobil 1 Fina  Shell Fleetmatic CD ATF 220 D  Dexron 
    IID 1 ATF or Dexron IID Dexron IID 
    ower steering 
    uid  reservoir 
    s applicable  DX 2D 
    Esso 
    Mobil  Fina  Shell  Super 
    Superlube  Super  Supergrade  Motor  Oil 
    (15W/40) 15W/40 Motor Oil 15W/40or 
    i 10W/40 or 1OW/40 15W/40or 1 OW/40 
    Duckhams 
    D-Matic 
    Duckhams 
    I5W/50 Hypergrade 
    Motor  Oil 
    iir cleaner -cyl. petrol UP Visco 
    (15W/40)or ßP Visco 
    (IOW130) BP Visco 
    (15W/40) or I BP Visco  Castrol 
    GTX (15W/5!)or Castrolite 
    Havoline 
    Motor  Oil 
    low130 or Eurotex  HD lowno 
    Havoline 
    Motor Oil 
    15 W/40 or 10W/30 or Eurotex  HD 1OW/30 
    ( 10 W/40) 
    ir cleaner -cyl. diesel Castrol GTX (15W150) or Castrolitc (I Uw140) 15W/40 or Owl40 
    rake and clutch 
    Universal  Bra ! Ihid or other brake  fluids having a minimum  boiling point of 260°C (500°F) 
    and comnlvine with  FMVSS 116 DOT 3 reservoirs 
    I Top link 
    .. 
    1  
    						
    							COMPONENTS I BP 
    retention clips Door lock striker 
    Windscreen 
    washers H 
    All Seasons  Screen Washer  Fluid  ~~ 
    Door 
    locks 
    (anti-burst) 
    Inertia  reels  ~ 
    ~~ ~ 
    - 
    ~~~~ 
    DO NOT LUBRICATE. These 
    components  are life  lubricated  at the  manufacturing  stage 
    API  service 
    levcls SE or SF or SEICC or SFICC or SEICD or SFKD or the CCMC 
    requirements  API 
    service  levels 
    CC or CD or SEICC or SE/CD or SFICC or SFICC or the CCMC 
    requirements 
    09 I RECOMMENDED LUBRICANTS, FLUIDSAND CAPACITIES 
    RECOMMENDED LUBRICANTS AND FLUIDS  SERVICE INSTRUCTIONS ALL MARKETS 
    ll CASTROL DUCKHAMS I ESSO 
    SPEC. REF. 
    TEXACO  BRANDS 
    Marfak  NGLI
    -2 ;; Multi- 
    MOBIL ~ Windscreen hinges 
    Ventilator  hinges 
    Ventilator  control 
    Seat  slides.  Hood BP Energrcase  LM Grease  LB 10 Multi- L2 purpose 
    Grease 
    1 Castrol 1 Duckhams 1 Esso 
    Mobil 
    Mobil- Shell 
    Marson  Retinax 
    HTL2 
    grease 
    MP 
    based 
    Bonnet 
    ointle I Graohite  Lock Grease Tvoe B 
    Battery  lugs 
    Earthing  surfaces 
    Where  paint has 
    been  removed  Petroleum 
    jelly. 
    NOTE: Do not  use Silicone  Grease 
    ~- 
    METHYLCHLORIDE REFRIGERANTS  MUST NOT BE USED 
    Air 
    Conditioning 
    System 
    Refrigerant 
    Compressor  Oil C .  ~ -- Use only refrigerant 
    12. This  includes  Freon 12 and Arcton 12 
    Shell Clavus 68 BP Energol LPT 68 Sunisco 4GS  Texaco Capella E Wax Free 68 
    RECOMMENDED LUBRICANTS AND FLUIDS 
    SERVICE  INSTRUCTIONS  FOR AMBIENT CONDITIONS OUTSIDE TEMPERATE CLIMATE  LIMITS 
    OR  FOR  MARKETS  WHERE THE PRODUCTS LISTED ARE NOT AVAILABLE 
    COMPONENTS  SERVICE 
    CLASSIFICATION  WORLDWIDE AiMßIENT TEMPERATURE C I 
    PERFORMANCE LEVEL SAE VISCOSITY -30 -20 -10 0 10 20 30 40 50 1 
    Engine 
    Carburetter 
    dashpotr Oil can 
    Oils 
    Oil  bath  air cleaners  Petrol 
    1 Diesel sw120 swi30 5 Wl40 
    10w130 
    10w140 low150 
    15w140 1sw150 
    20W/40 20Wi50 
    oils must meet ßL I Oils must 
    meet BI. Cars spec.  Cars spec. BLS.22.OL.02 BLS.22.OL.02 an( or MIL-L-461S2A or 
    Power  steering 
    reservoir  ATF M2C 33 
    For  G  ~~~ 
    Front 
    and rear 
    Axle  differential 
    Swivel  pin housing 
    LT230 transfer bo, Steering box  API 
    GL4 
    or MIL-Ir2105 
    90 EI 
    80W EP 
    LI77 eearbox ATF M2C 33 F or G 
    Ll%iearbox including :ransfer box  Oils 
    must 
    mcet BL Cars spec. BLS.22.OL.02 or API service  levels 
    SE or SF or SE/CC or SEICD or SF/CC or SFICD or the  CCMC 
    10W130 IOW140 IOWlS0 
    IOW140 IOW150 1sw140 15w150 2ow140 20w150 
    requirements 
    LT85 gearbox - V8 cylinder  Oils must 
    meet ßL 1ow130 10w140 1ow15o Cars spec. BLS.22.OL.02 or 
    API servicc levels SE or SF or SEICC ?r SE!C_n or SE!CC 3r SWCD or thc XMC requirements 
    Brake  fluid must  have  a minimum  boiling point 
    of 260°C (500°F) and  comply with FMVSS 116 DOT 3 
    VLGI
    -2  multipurpose  lithium based grease 
    3rake and clutch eservoirs 
    xbrication nipples 
    hubs,  ball joints, etc) 
    2  
    						
    							RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES 109 I 
    - . !.. 
    :.. .!, 
    .I I, .. .. I. ....... I. . 
    . _. .... .. .. ..... .. I .., .... :. : ....... 
    . (. . ....... ., ..,? , . .... ..... 
    ANTI-FREEZE 
    Use  only UNIVERSAL  Anti-freeze or an  Ethylene  Glycol based  anti-freeze,  containing no methanol, with 
    non-Phosphate  corrosion inhibitors suitable  for use  in cast  iron  and aluminium  alloy engines  to ensure  protection of 
    the cooling  system against  frost and corrosion. 
    Percentage 
    Engine  Mixture Concentration Protection 
    One part anti-freeze two parts  water  33% Down to -20°C 
    One  part anti
    -freeze  one part  water 50% Below -20°C  to 
    One  part anti
    -freeze  one part  water 50%  Down  to -36°C 
    -36°C i 
    4-cyl. Engines  (cast iron) 
    V8 Engine  (aluminium) 
    IMPORTANT:  Coolant solution  must not fall  below  proportions  of one  part  anti-freeze  to three  parts water, i.e. min. 
    25 anti-freeze  in coolant,  otherwise  damage to engine is liable to occur. 
    CORROSION  INHIBITOR 
    When anti-freeze is not required  the cooling  system must  be flushed  out with  clean water and  filled with a solution of 
    ONE PART MARSTONS SQ 36 inhibitor to NINE  parts water  to provide  a 10 mixture  concentration. 
    CAPACITIES 
    The following capacity  figures  are approximate and are provided  as a guide only. All oil levels must  be set using the 
    dipstick  or level plugs 
    as applicable. 
    Component  Litres Imperial unit 
    Engine sump oil, 4-cylinder.. ............................................. 
    Extra  when  refilling  after fitting  new filter, 4-cylinder.. ............ 
    Air cleaner  oil, 4-cylinder ................................................. 
    Extra when  refilling after fitting new filter, V8 cylinder.. .......... 
    Main  gearbox oil,  five-speed ............................................. 
    Engine sump oil, V8 cylinder ............................................. 
    Transfer  box oil, LT230R five-speed  main gearbox.. ............... 
    LT85  five-speed  gearbox .................................................. 
    LT230T transfer  gearbox .................................................. 
    Main gearbox  oil, four-speed ............................................. 
    Transfer gearbox  oil, four-speed  main gearbox ...................... 
    Front differential ............................................................ 
    Rear  differential:  Salisbury 8HA ........................................ 
    Swivel pin housing oil (each) ............................................. 
    Fuel  tank,  rear ............................................................... 
    Fuel tank,  side (except  Station wagon) ................................. 
    Fuel tank,  side (Station  wagon only) .................................. 
    Cooling system, 4-cylinder  petrol models  (standard) ............... 
    Cooling  system, 4-cylinder  diesel models  and heavy  duty 
    petrol models 
    .............................................................. 
    Cooling  system, V8 cylinder modcls.. .................................. 
    Steering  box manual.. ...................................................... 
    Power  steering  box and reservoir  fluid ................................. 
    6,OO 
    0,85 
    0,85 
    5,lO 
    0,56 
    2,20 
    2,80 
    3,OO 
    2,80 
    2,60 
    3,16 
    1,70 
    2,30 
    0,35 
    79,50 
    68,20 
    45,50 
    10,30 
    11 ,oo 
    12,80 
    O,43 
    2,90 
    11 .OO pints 
    1.50 pints 
    1.50 pints 
    9.00  pints 
    1.00 pint 
    3.90  pints 
    4.90  pints 
    5.25  pints 
    4.9  pints 
    4.70  pints 
    5.50 pints 
    3.00  pints 
    4.00 pints 
    0.60  pint 
    17.50  gallons 
    15.00 gallons 
    10.00 gallons 
    18.00  pints 
    19.00  pints 
    22.50  pints 
    5.0 pints 
    0.75 pints 
    3  
    						
    							MAINTENANCE I 10 I 
    MAINTENANCE SCHEDULES 
    Revised Maintenance  Schedules are introduced  with the commencement  of the Land Rover  Ninety V8 model range. 
    The  new  schedules  also apply  to four
    -cylinder,  petrol and diesel  models,  and  feature  a reduced  10.000 km 
    (6,000  miles)  service. The new  schedules  supersede  previous issues. 
    Efficient  maintenance  is one 
    of the  biggest  factors in ensuring  continuing  reliability  and efficiency. For  this  reason 
    the  following  detailed schedules are  included 
    so that at the  appropriate  intervals owners  and  operators may  know 
    what 
    is required.  The Maintenance  Schedules  are  based upon intervals of 10.000 km (6,000 miles) or 6 months 
    unless  otherwise  stated. 
    Note:  The 
    10.000 km service  must be repeated  every 10.000 km (6,000 miles)  or six  months,  whichever  is first. 
    The  20.000 
    km service  must be repeated  every  20.000 km (12.000 miles) or 12 months,  whichever  is first,  with 
    additional  maintenance  at the  intervals specified  in the  schedule. 
    Every  Every 1O.OOo km 20.000 km (6.0 miles) (12.000 miles) or6months or 12months 
    1 
    2 
    3  Check operation of horns 
    4 
    5 
    6 
    7 
    8 0 Check  rear view mirror(s) for security, 
    9 
    0 Check  condition  and security  of seats,  seat 
    0 Check operation of all lamps 
    a Check operation  of warning  indicators 
    0 Check operation  of windscreen  and rear 
    0 Check  condition  of wiper  blades 
    0 Check  security  and operation of handbrake 
    belt 
    mountings, seat  belts and buckles 
    wipers  and washers 
    cracks  and crazing 
    tailgate locks 
    10 
    0 Check operation of window  controls 
    11 0 n Lubricate  all locks (not steering lock) 
    hinges  and door - check mechanisms 
    12 
    0 Lubricate  accelerator control linkage and 
    pedal  pivot 
    13 
    14 0 ChecWadjust  headlamp alignment 
    15 0 Check front wheel  alignment 
    16 
    17 0 Remove  battery connections, clean  and 
    18 
    0 Removeroadwheels 
    0 Check operation of all doors, bonnet  and 
    0 ChecWadjust  tyre pressures  including spare 
    a 0 ChecWtop-up battery electrolyte 
    grease (refit) 
    . 19 
    20 
    21 
    22 
    23 
    24 
    25  26 
    27 
    28 
    29 
    U 
    U 
    0 
    0 
    0 
    0 
    0 
    0 
    n 
    n 
    0 
    0 
    Check tyres  comply with Manufacturers 
    specification 
    Check  tyres visually  for cuts,  lumps, bulges, 
    uneven  wear and tread  depth 
    Remove  road wheel  brake drums,  wash out 
    dust,  inspect shoes for wear  and drums  for 
    condition 
    Inspect  wheel cylinders  for fluid  leaks 
    Inspect  brake pads for wear,  calipers for 
    leaks,  and discs  for condition 
    Refit  road wheel  brake drums 
    Adjust road  wheel brakes 
    Adjust  handbrake 
    if required 
    Refit road  wheels to original  position 
    Renew engine 
    oil 
    Renew engine  oil filter 
    Every 4O.wO km 30 24.000ml Renew gearbox oil 
    Every  Every 1O.ooO km 20.000 km (6.000 miles) (12,000 miles) or6months or 12month; -- 31 U U Every 40.000 km 32 24.000 ml 
    33 a 0 
    35 0 0 
    37 0 0 
    39 0 0 
    Every 40.003 km 34 24.lXXl ml 
    Every 4O.lXK) km 36 24.WOml 
    Every 40.000 km 38 24,~ml 
    40 a 0 
    42 0 
    Every 4O.OlKl km 41 24.000 ml 
    43 0 0 
    44 D 
    45 U 
    46 U 
    47 0 0 
    48 U 
    49 0 
    50 U 
    51 U 
    - U Every 80.0W km 52 
    53 48,000 ml 
    54 U 
    55 I 
    56 0 
    58 U 
    Every40.000 km 59 24.000ml 
    ChecWtop-up gearbox oil 
    Renew transfer  box oil 
    CheeWtop-up transfer  box oil 
    Renew  front axle  oil 
    ChecWtop
    -up  front  axlc oil 
    Renew  swivel pin housing oil 
    ChecWtop
    -up  swivel  pin housing oil 
    Renew  rear axle oil 
    ChecWtop
    -up  rear  axle oil 
    Lubricate  rear suspension  upper link ball joint 
    Lubricate propeller 
    shaft sealed  sliding  joints 
    Lubricate  propeller shaft universal  joints 
    Lubricate  handbrake  mechanical  linkage 
    Check  visually 
    brakc, fuel, clutch pipeshnions for chafing, leaks and corrosion 
    Check  exhaust  system 
    for leakage and 
    security 
    Check  for oil leaks  from engine  and 
    transmission 
    Check 
    for oil/fluid leaks  from stcering and 
    suspension systems 
    Check axlc  breather pipes, ensure  they arc 
    not  blocked,  pinched 
    or split 
    Check security and condition 
    of suspension 
    fixings 
    Check condition  and security  of steering unit, 
    joints  and gaiters 
    Check tightness 
    of propeller shaft coupling 
    bolts 
    Clean 
    fuel sedimenter  (Diesel only) 
    Clean  electric fuel pump  filter 
    Renew  fuel filter  element (Petrol) 
    Drain  flywheel housing  if drain  plug is  fitted 
    for  wading  (refit) 
    Clean camshaft drive  belt  housing filter 
    (Diesel) 
    Check 
    c~ndltien ef heater p!~g wiring fs: 
    fraying,  chafing and deterioration 
    (diesel only) 
    Remove  heater plugs, clean, test and refit 
    (diesel only) 
    Remove  diesel injectors, clean,  test and refit 
    1  
    						
    							El MAINTENANCE 
    Every  Every 1O.ooO km 20.000 km (6.000 miles) (12.000 miles) or 6 months or I2 months 
    0 Renew fuel filter  element (Diesel) - 60 
    Every  Every IO.o(K) km 2O.ooO km (6.000 miles) ~12.ooO miles) or 6 months br 12 months 
    61 
    62 
    0 Cleardadjust spark  plugs 
    63 
    0 Renew  spark plugs 
    64 
    0 Renew air  cleaner elements 
    65 
    66 
    24,001) ml Renew  engine breather  filter (V8) 
    67 0 Clean engine  breather  filter (all models 
    except 
    V8) 
    Checkladjust valve  clearance (all models 
    except V8) 
    0 Check  air cleaner  dump valve,  clean or renew EveryJ0.000 km 
    0 Renew engine  flame trap(s) (V8) 68 Every60.000 km 69 36.000ml Renew brake Servo filter 
    70 
    71 
    72 
    73 
    74  Top
    -up carburetter piston dampers 
    75 
    0 ChecWtop-up cooling system 
    76 
    0 0 Checktop-up  fluid  in power  steering  reservoir 
    77 
    78 
    0 ChecWadjust  steering box 
    79 
    0 0 Check/top-up clutch  fluid reservoir 
    80 0 0 Checktop-up brake  fluid reservoir 
    81 0 0 Check/top-up windscreen  and  rear washer 
    reservoir 
    82 0 Check  cooling  and heater  system  for leaks, hoscs for security  and condition 
    83 0 0 Check power steering  system for leaks, 
    hydraulic  pipes and unions  for chafing and 
    corrosion 
    Check condition  of driving  belts 
    - adjust if required (not  camshaft drive belt - diesel) 
    0 Check  ignition wiring  and HT leads for 
    fraying, chafing and  deterioration 
    0 Clean distributor  cap,  check for cracks and 
    tracking  Check 
    brake 
    Servo hose for security  and 
    condition 
    hoses/pipes for  security  and condition 
    n Check air injection/pulsair system 
    0 Check  operation  of pulsair check valves 
    hoses  for security and  condition 
    0 0 Check crankcase breathing  system for leaks, 
    0 Checktop-up steering  box (manual steering) 
    84 
    85 
    86 
    0 0 
    87 
    88 
    24.lXM ml Renew distributor  points (not V8) 
    89 Lubricate  distributor  (not V8) 
    90 
    91 
    0 Check dwell angle -adjust as necessary 
    92 
    0 0 ChecWadjust  ignition timing 
    0 Clean/adjust distributor points (not V8) Every 41.000 km 
    Check voltage  drop between coil CB and earth 
    (not 
    V8) 
    Note: It  is important that the  ignition  timing, 
    dwell  angle  and carburetter adjustments  are set 
    in  accordance  with the vehicle engine 
    spenfcation and fuel Octane  rating. Refer to the  relevant repair 
    operation manual 
    for details 
    93 
    a Check  throttle  operation 
    94 0 0 ChecWadjust  engine idle speed,  and 
    carburetter mixture  settings with engine at 
    normal  running temperature 
    Check  operation 
    of air intake temperature 
    control  system 
    (V8) Carry out road or roller  test - Check: 
    95 
    0 
    96 0 0 For excessive 
    engine noise 
    97 
    0 0 Clutch for slippindjudder/spinning 
    98 0 0 Gear selectiodnoise - high  and low range 
    99 0 0 Steering for noise/abnormal effort required 
    100 0 0 All instruments,  pressure,  fuel and 
    101 
    102 
    0 0 Heatedrearscreen 
    103 
    104 
    0 0 Foot  brake, on emergency  stop, pulling  to 
    one side,  binding, pedal effort 
    105 0 0 Handbrakeefficiency 
    106 
    0 0 Operation  of inertia  seat belts 
    107 
    a Roadwheel  balance 
    108 0 0 Transmission  for vibrations 
    109 
    0 0 For body noises  (squeaks and rattles) 
    110 0 0 Fuel governor  cut-off point 
    111 0 0 For excessive  exhaust smoke 
    112 
    0 0 Engineidlespecd 
    113 0 Endorse  service rccord 
    114 0 a Report any additional  work required 
    temperature gauges, 
    warning indicators 
    0 0 Heater and air  conditioning  systems 
    0 0 Shock absorbers  (irregularities in ride) 
    c3 a.: -.:/ 
    WARNING:  Two-wheel  roller tests must  be restricted to 5 kdh (3 m.p.h.) because the  Land  Rover One  Ten  and 
    Ninety 
    is  is constant four-wheel drive. 
    At 100.000 km (60?000 mile)  intervals  it  is imperative  that the camshaft  drive  belt be renewed,  failure to do so 
    could result  in serious engine damage. 
    RECOMMENDATIONS 
    At  30.000 km (18,000 mile) intervals  or every 18 months, whichevcr is the sooner, the  hydraulic brake  fluid should 
    be  completely  renewed. 
    At  40.000 
    km (24,000  mile)  intervals  remove the Pulsair injection manifold  and connecting pipes,  ensure that the 
    internal  bores  and  the cylinder  head drillings  are clean  and free  from  obstructions,  clean 
    as necessary and  refit. 
    (Emission control 
    V8 petrol  engines) 
    At  60.000 
    km (36,000 mile)  intervals or every 3 years,  whichever  is the sooncr, all  hydraulic  brake fluid, seals and 
    flexible  hoses should  be renewed.  all working surfaces 
    of the master  cylinder, wheel cylinders and caliper cy!inders 
    should  be examined and renewed where  necessary. 
    At 
    60.000 km (36,000 mile)  intervals  remove all suspension  dampers, test for correct  operation,  refit or renew  as 
    necessary. 
    Vehicles fitted with free wheeling front hubs 
    The  hubs  require  no routine  maintenance.  When  the hub  bearings  are adjusted, or any time the  vehicle has been 
    used  for wading,  the moving  parts 
    of the  free  wheel hubs should  be lightly  smeared  with Rocol 1000 grease or a 
    similar  molybdenum disulphide  bearing grease. 
    2 
    &-? E.  -.. I  
    						
    							MAINTENANCE Gi 
    ,;:,,.::.>, T LUBRICATION a;,-;;. :? . ., ... . . .. 
    This first part of the maintenance  section  covers 
    renewal 
    of lubricating  oils for the  major  units  of the 
    vehicle  and other  components  that require lubrication, 
    as  detailed 
    in the ‘Maintenance  schedules’. Refer to the 
    ‘General  specification  data’ for  capacities  and 
    recommended  lubricants. 
    Vehicles  operating  under  severe conditions  of dust, 
    sand, mud  and water should  have  the oils changed and 
    lubrication  carried out at more  frequent  intervals than 
    that recommended  in the  maintenance schedules. 
    Draining 
    of used oil should  take place  after a run  when 
    the 
    oil is  warm.  Always  clean  the  drain and filler-level 
    plugs  before  removing.  In the  interests 
    of safety 
    disconnect  the vehicle  battery  to  prevent the engine 
    being  started  and  the  vehicle moved inadvertently, 
    while oil  changing  is taking place. 
    Allow  as much  time as possible  for  the 
    oil to drain 
    completely except  where blown sand or dirt  can enter 
    the  drain  holes. 
    In these  conditions  clean and refit  the 
    drain  plugs  immediately  the main  bulk of oil  has 
    drained. 
    Where  possible,  always refill  with  oil 
    of the make  and 
    specification  recommended  in the  lubrication  charts 
    and from sealed  containers. 
    T. 
    . 
    						
    							1x1 MAINTENANCE 
    Renew oil filter - 2.25 petrol  and diesel engine 
    RENEW MAIN AND TRANSFER  GEARBOX OILS 
    DRAIN 
    AND REFILL LT77mm MAIN  GEARBOX 
    4
    -cylinder engines 
    @ 8. Place  oil tray  under  engine. 
    9.  Unscrew  filter retaining bolt. 
    10.  Remove  the container. 
    11. Remove the element. 
    12.  Discard  the used  filter  element and  large  rubber 
    washer. 
    13. Wash the container  in kerosene. 
    14.  Place  the new  filter  element  in the  container  and 
    reassemble  the unit,  using  the new  large  rubber 
    washer  supplied with  the element. 
    15. Ensure  that all the  sealing  washers  are in position 
    and  intact,  and that  the container  is correctly 
    located  in the  adaptor. 
    16. Tighten  the  filter  retaining  bolt to  the  correct 
    torque. 
    Do not overtighten. 
    Sl 
    Refill  sump  with oil -all models 
    1. Drive  the vehicle  to level  ground  and place  a 
    suitable  container  under  the gearbox  to catch  the 
    old oil. 
    2.  Remove  the gearbox  and extension  case  drain 
    plugs  and allow  the oil to drain  completely.  Wash 
    the  extension  case  filter  in  kerosene  and  refit  the 
    plugs  using  new  washers, if necessary,  and tighten 
    to the correct  torque. 
    ST 919M U 
    3. Remove  the oil filler-level plug and inject  the 
    approximate  quantity 
    of new  oil of the  correct 
    make  and grade  until 
    it begins to run out of the 
    filler
    -level  hole. Fit the plug  and  tighten to  the 
    coirect torque. Since the plug  has a tapered  thread 
    it must not be overtightened.  Wipe away any 
    surplus  oil. 
    17. Check that  the drain  plug is tight. 
    18. Clean  the  outside of the oil filler cap, remove  it 
    from the  rocker cover and clean  the inside. 
    19.  Pour  in the  correct  quantity  of new  oil 
    of the 
    correct  grade from  a sealed  container  to the  high 
    mark 
    on the  dipstick  and firmly  replace  the filler 
    cap. 
    20. 
    Run the  engine  and check  for leaks from  the filter. 
    Stop  the engine,  allow the oil 
    to run back  into the 
    sump  for a few  minutes,  then check  the 
    oil level 
    again  and top 
    up if necessary. 
    4  
    						
    							MAINTENANCE 110 I 
    DRAIN AND  RENEW  230R  AND  230T TRANSFER 
    GEARBOX 
    (4-cylinder engine) 
    1. Drive  the vehicle  to level  ground  and place a 
    container  under the  gearbox to catch the old oil. 
    2. Remove  the  drain  plug and allow  the oil to drain. 
    Fit  the  plug  using  a new  washer, 
    if necessary,  and 
    tighten  to the correct  torque. 
    3.  Remove  the  filler
    -level plug and  inject  the 
    approximate quantity 
    of the  recommended  oil until 
    it  begins  to run  from  the plug  hole.  Fit the  level 
    plug  and tighten only 
    to the correct  torque,  do not 
    overtighten,  wipe away 
    any surplus  oil. 
    ST1070M 
    DRAIN  AND RENEW LT95 MAIN GEARBOX (V8 
    engines) 
    1. Drive  the  vehicle to level  ground  and  place a 
    container under  the gearbox to  catch the old oil. 
    2. Remove  the drain  plug,  washer and  filter from the 
    bottom  of the  gearbox  casing  and  allow the 
    oil to 
    drain  completely. 
    3. Wash  the filter  in petrol,  allow to dry and  fit to the 
    casing.  Using a  new  washer,  if necessary,  fit the 
    plug  and tighten  to the  correct  torque. 
    4. Remove  the oil filler-level  plug from  the side of the 
    gearbox  and inject  the approximate quantity 
    of the 
    correct  oil until  it begins  to run  from  the filler
    -level 
    hole.  Clean  and refit  the plug  using 
    a new washer 
    and  tighten  to the  correct  torque. Wipe  away  any 
    surplus  oil. 
    DRAIN  AND RENEW LT95 TRANSFER  GEARBOX 
    OIL 
    1. Drive  vehicle  to level  ground and  place a container 
    beneath  the gearbox  to catch  the old oil. 
    2. Remove  the drain  plug and allow  time for the oil to 
    drain  completely. 
    3.  Clean and  refit the drain plug  using a new  washer, 
    if  necessary  and tighten 
    to the correct  torque. 
    4. Remove  the oil  filler-level  plug and inject  the 
    approximate  quantity 
    of a recommended oil until  it 
    begins  to run  from the hole.  Clean and fit the  plug 
    and  tighten  to the  correct  torque. 
    Do not 
    overtighten.  Wipe away any surplus  oil. 
    RENEW FRONT AND REAR AXLE OIL 
    1. Drive  the  vehicle to level  ground  and  place  a 
    container under the  axle to be  drained. 
    2. Using  a spanner  with a 13 mm (0.5 in) square  drive 
    remove  the  drain plug and allow  the oil to drain 
    completely. Clean and  refit the drain  plug. 
    3. Remove  the oil filler-level  plug and  inject  new  oil 
    of  a recommended make  and grade  until it begins 
    to  run  from  the hole.  Clean  and fit the  filler
    -level 
    plug  and wipe  away  any 
    surplus oil. 
    NOTE: Whilst the illustration shows a ‘90’ model 
    front differential, the procedure is the same for all 
    axles. 
    5  
    						
    							El MAINTENANCE 
    RENEW SWIVEL  PIN HOUSING OIL 
    1. Drive  the vehicle to level ground  and  place a 
    container  under  each  swivel housing  to  catch  the 
    used 
    oil. 
    2. Remove  the  drain  plug and allow  the oil to drain 
    completely and  clean and refit  the plugs. 
    3. Remove  the oil  filler-level  plug and  inject  the 
    recommended  make  and  grade 
    of oil  until  oil 
    begins  to run  from  the level  hole.  Clean  and fit the 
    level plugs  and wipe  away  any surplus  oil. 
    LUBRICATE  PROPELLER  SHAFTS 
    1. Clean all the  grease  nipples on the  front  and  rear 
    propshaft  universal joints, and sliding  portion  of 
    the  rear  shaft. 
    2. Charge  a low  pressure  hand grease  gun  with grease 
    of a recommended  make  and grade  and  apply to 
    the grease nipples. 
    3. Remove  the screwed  plug  from  the front shaft and 
    fit 
    a suitable grease nipple. 
    4. Disconnect  one end of the  front propeller shaft and 
    compress  the sliding  portion  whilst applying 
    grease.  It is necessary  to compress  the  shaft  to 
    prevent 
    over filling with  grease. It should be noted 
    that  this  sliding  portion must only be lubricated  at 
    40.000 km (24,000 mile) intervals. 
    5. Reconncct the propeller  shaft, remove the grease 
    nipple and 
    fit the  screwed plug. 
    TOP-UP MANUAL  STEERING BOX 
    1. Remove the oil filler  plug and observe  the oil  level 
    which  should  be 
    25 mm (1.0 in) below  the top of 
    the  filler  hole. 
    2. If necessary  top-up to the  correct  level with a 
    recommended  oil.  Clean and refit the plug  and 
    wipe  away any  surplus oil. 
    ST 925M // 
    RENEW  AIR CLEANER OIL - 2.25 litre engines 
    (early models) 
    1. Slacken  wing nut and  release  the  clamping  strap 
    securing  the complete  air cleaner. 
    2. Disconnect the outlet  elbow  from the intake  pipe 
    and  remove the 
    clcaner from thc vehicle. 
    3. Remove  the oil bowl  from  the bottom  of the 
    cleaner  by releasing  the three  securing clips. 
    4. Clean all dirty oil and sludge  from the bowl  and 
    refill  with  fresh engine 
    oil to the  level  indicated  by 
    a ring formed  in the  pressing;  the capacity  is 
    approximately 
    0,85 litre (1.5 imperial  pints). 
    5. Clean the spiral  in the cleaner  body  by  swilling  the 
    complete  body  in paraffin  and  shake off the 
    ct 
    6. Remove  and clean  the air intake cap. 
    7. Clean the wire mesh  filter. 
    8. Reassemble filter  using a new  scaling  ring. 
    9. Refit the complete  unit into  the vehicle. 
    surplus. 
    -d 
    6  
    						
    							MAINTENANCE I 10 I 
    L7Xp :. 
    ..:? Diesel engine 
    TOP
    -UP 
    BRAKE  VACUUM  PUMP OIL - 2.25 litre 
    TOP-UP CARBURETTER  PISTON DAMPER - V8 
    only . .. . ..-I 1.1, 
    1. Slacken the drive  belt,  and  the pump  pivot bolts 1. Unscrew  the  cap on top  of both  suction  chambers 
    and  withdraw  the damper. 
    2. Move  the  pump to an upright  position  and 2. Top-up the reservoir  with engine  oil to within 
    12 mm (0.5 in)  from  the top  of the  hollow  piston 
    rod.  Refit 
    the damper  and secure  the cap. 
    and 
    nuts and slip  the belt  from  the pulley. 
    temporarily  tighten  the nuts  and  bolts 
    to maintain 
    this  position. 
    3. Turn  the pump  pulley so that  the  indicating  marks 
    on  the  pulley  hub and pump  body line up. 
    - . .. ,. . .. .. I, :, : 
    .. . .~ ... .._ ,* .. . .. .. . 
    3 
    4. Remove the  oil level  plug  at the  rear  of the pump 
    and 
    if necessary  inject  a  recommended  SAE 
    15W-50 oil up to the level of the  hole. 
    5. Refit  the  level plug,  and fit and  tension  the drive 
    belt. 
    ST 
    4 
    1008M 
    /4 
    REAR  SUSPENSION  BALL JOINT 
    1. Apply  a grease  gun to the  nipple  using a 
    recommended grease. 
    RENEW LT85 MAIN  GEARBOX  OIL 
    Drain  and refill monthly when  operating under severe 
    wading  conditions. 
    To  change  the 
    gcarbox oil proceed  as follows: 
    1. Immediately after a run when  the oil is warm,  drain 
    off the oil into a container  by removing  the  drain 
    plug  and washer  from the bottom  of the  gearbox 
    casing. 
    2. Remove  the oil filter. 
    3. Wash  the filter in clean  fuel; allow  to dry  and 
    replace. 
    4. Clean  and refit  drain  plug  and  washer and refill 
    gearbox  through the 
    oil level/filler plug,  with  the 
    correct  grade  of oil,  to the  bottom 
    of the oil 
    1eveYfiller hole. For capacity see Data  Section. 
    7  
    						
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