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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

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    							10MAINTENANCE
    12
    MAINTENANCE AUXILIARY DRIVE BELT
    Check
    1.Check auxiliary drive belt for signs of splits,
    fraying, oil contamination and wear.
    NOTE: Any requirement to replace the
    auxiliary drive belt 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.
    Renew
    1.Renew auxiliary drive belt.See ELECTRICAL,
    Repair.
    NOTE: Additional time is built into the
    96,000/8 year service time to allow for
    auxiliary drive belt renewal.PAS FLUID, CLUTCH FLUID AND SCREEN
    WASHER LEVELS
    PAS Fluid
    1.Clean arear around PAS reservoir filler cap, and
    remove cap.
    2.Check fluid level in PAS reservoir.
    3.Top-up if necessary to the correct level using
    recommended fluid.See LUBRICANTS,
    FLUIDS AND CAPACITIES, Information.
    4.Fit filler cap. 
    						
    							MAINTENANCE
    13
    MAINTENANCE Clutch Fluid
    1.Clean area around clutch fluid reservoir cap, and
    remove cap.
    2.Check fluid level in clutch fluid reservoir.
    3.Top-up if necessary to the correct level using
    recommended fluid.See LUBRICANTS,
    FLUIDS AND CAPACITIES, Information.
    4.Fit filler cap.
    Screen Washer Fluid
    1.Clean area around washer fluid filler cap.
    2.Check washer fluid level in reservoir.
    3.Top-up if necessary to the correct level using
    recommended fluid.See LUBRICANTS,
    FLUIDS AND CAPACITIES, Information.
    4.Fit filler cap.STEERING BOX
    Check
    1.Check steering box for fluid leaks.
    Adjust
    1.Check there is no backlash in steering box with
    the road wheels in the straight ahead position.
    Adjust if necessary.See STEERING,
    Adjustment. 
    						
    							10MAINTENANCE
    14
    MAINTENANCE ENGINE OIL
    WARNING: Avoid excessive skin contact
    with used engine oil. Used engine oil
    contains potentially harmful contaminants
    which may cause skin cancer or other serious
    skin disorders.
    1.Remove underbelly panel.See CHASSIS AND
    BODY, Repair.
    2.Position suitable container beneath sump.
    3.Clean arear around drain plug.
    4.Remove oil drain plug, discard sealing washer.
    5.Allow oil to drain.
    6.Fit new sealing washer to oil drain plug.
    7.Fit engine drain plug and tighten to23 Nm (17
    lbf.ft).
    8.Fill engine with recommended grade of oil to
    correct mark on dipstick.See LUBRICANTS,
    FLUIDS AND CAPACITIES, Information.
    9.Fit underbelly panel.See CHASSIS AND
    BODY, Repair.CENTRIFUGE ROTOR - Td5
    1.Renew centrifuge rotor.See ENGINE , Repair. 
    						
    							MAINTENANCE
    15
    MAINTENANCE FULL FLOW OIL FILTER
    1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
    WARNING: Avoid excessive skin contact
    with used gearbox oil. Used gearbox oil
    contains potentially harmful contaminants
    which may cause skin cancer or other serious
    skin disorders.
    1.Renew gearbox oil.See MANUAL GEARBOX,
    Adjustment. 
    						
    							10MAINTENANCE
    16
    MAINTENANCE TRANSFER BOX OIL
    WARNING: Avoid excessive skin contact
    with mineral oil. Mineral oils remove the
    natural fats from the skin, leading to
    dryness, irritation and dermatitis.
    Check
    1.Remove underbelly panel.See CHASSIS AND
    BODY, Repair.
    2.Clean area around oil filler/level plug.
    3.Remove oil filler/level plug.
    4.Check that oil level is to bottom of oil filler/level
    plug hole.
    5.Remove all traces of sealant from threads of oil
    filler/level plug.
    6.Apply Loctite 290 to threads of oil filler/level plug
    and tighten to25 Nm (18 lbf.ft).
    7.Remove all traces of oil from main casing.
    8.Fit underbelly panel.See CHASSIS AND
    BODY, Repair.Renew
    1.Remove underbelly panel.See CHASSIS AND
    BODY, Repair.
    2.Place a suitable container beneath transfer box
    to catch any fluid spillage.
    3.Clean area around oil filler/level and drain plugs.
    4.Remove oil filler/level plug.
    5.Remove oil drain plug.
    6.Allow oil to drain.
    7.Apply Loctite 290 to threads of oil drain plug.
    8.Fit transfer box drain plug and tighten to30 Nm
    (22 lbf.ft).
    9.Fill transfer box with recommended oil to bottom
    of oil filler/level plug hole.See LUBRICANTS,
    FLUIDS AND CAPACITIES, Information.
    10.Remove all traces of sealant from threads of oil
    filler/level plug.
    11.Apply Loctite 290 to threads of oil filler/level plug
    and tighten to25 Nm (18 lbf.ft).
    12.Remove all traces of oil from main casing.
    13.Fit underbelly panel.See CHASSIS AND
    BODY, Repair. 
    						
    							MAINTENANCE
    17
    MAINTENANCE FRONT AND REAR AXLE OIL
    Renew
    A- Front and rear axle, 90 models, front, 110/130
    models.
    B- Rear axle, 110/130 models.
    WARNING: Avoid excessive skin contact
    with used axle oil. Used axle oil contains
    potentially harmful contaminants which
    may cause skin cancer or other serious skin
    disorders.1.Ensure vehicle is level and place suitable tray
    under axle to be drained.
    2.Using 13mm square drive wrench, remove drain
    and filler/level plugs from axle and allow oil to
    drain completely.
    3.Clean and refit drain plug.
    4.Inject new oil, until it runs out from filler/level
    hole. Allow excess oil to drain and wipe clean.
    See LUBRICANTS, FLUIDS AND
    CAPACITIES, Information.
    5.Clean and refit filler/level plug.
    Check
    1.Ensure vehicle is level.
    2.Using 13 mm square drive wrench, remove
    filler/level plug.
    3.If necessary inject new oiluntil oil runs out from
    filler/level hole. Allow excess oil to drain and
    wipe clean.See LUBRICANTS, FLUIDS AND
    CAPACITIES, Information.
    4.Clean and refit filler/level plug. 
    						
    							10MAINTENANCE
    18
    MAINTENANCE PROPELLER SHAFTS
    1.Clean area around front universal joint grease
    nipple.
    2.Apply recommended grease to the grease
    nipple.See LUBRICANTS, FLUIDS AND
    CAPACITIES, Information.CLUTCH PIPES AND UNIONS
    Check
    1.Check route of clutch pipe from master cylinder
    to slave cylinder. Ensure that pipe is correctly
    retained and shows no signs of fluid leakage or
    chafing.
    2.Check unions for signs of fluid leakage. 
    						
    							MAINTENANCE
    19
    MAINTENANCE PAS PIPES AND UNIONS
    Check
    1.Check PAS pipes for correct, secure routing and
    signs of chafing.
    2.Check for signs of fluid leakage from PAS pump,
    hoses, and hose unions.ENGINE, GEARBOX, TRANSFER BOX AND AXLES
    Check
    1.Check for oil leaks from engine, gearbox, tansfer
    box, and front and rear axles. Pay particular
    attention to areas around oil seals. 
    						
    							10MAINTENANCE
    20
    MAINTENANCE EXHAUST SYSTEM
    1.Visually check condition of exhaust system for
    signs of damage.
    2.Check condition of exhaust heat shields.
    3.Check exhaust system is firmly secured and
    check condition of exhaust mounting rubbers,
    clamps and brackets.STEERING BOX AND SUSPENSION
    1.Check steering box fixings. Tighten if necessary
    to81 Nm (60 lbf.ft).
    2.Check LH and RH front radius arm fixings.
    Tighten if necessary.See FRONT
    SUSPENSION, Repair.
    3.Check Panhard rod fixings. Tighten if necessary.
    See FRONT SUSPENSION, Repair.
    4.Check all rear axle fixings. Tighten if necessary. 
    						
    							MAINTENANCE
    21
    MAINTENANCE STEERING BALL JOINTS
    1.Check for wear in joints by moving ball joint up
    and down vigorously. If free movement is
    apparent, fit a new joint assembly.
    2.Check condition of steering ball joints paying
    particular attention to dust covers.
    NOTE: Any requirement to replace the
    steering ball joints 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.
    NOTE: Ball joints are lubricated for life
    during manufacture and require no further
    lubrication unless the rubber boot has
    been dislodged or damaged. All joints should be
    checked at specified service intervals, but more
    frequently if vehicle is used under arduous
    conditions. 
    						
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