Defender 300Tdi (1996+). Manual — part 11
MAINTENANCE
3
MAINTENANCE
UNDER BONNET MAINTENANCE
UNDER BONNET COMPONENTS
A - RH drive
1. Brake fluid reservoir
2. Clutch fluid reservoir
3. Air cleaner element
4. Engine breather filter
5. Oil filler cap
6. Oil level dipstick
7. Heater/air conditioning unit
8. Windscreen washer reservoir
9. Power steering pump reservoir
10. Intercooler and hoses
11. Radiator filler plug
12. Radiator
13. Oil cooler
14. Fuel filter
15. Accelerator linkage
16. Expansion tank
17. Air cleaner dump valve
10
MAINTENANCE
4
MAINTENANCE
UNDER BONNET COMPONENTS
B - LH drive
1. Brake fluid reservoir
2. Clutch fluid reservoir
3. Air cleaner element
4. Engine breather filter
5. Oil filler cap
6. Oil level dipstick
7. Heater/air conditioning unit
8. Windscreen washer reservoir
9. Power steering pump reservoir
10. Intercooler and hoses
11. Radiator filler plug
12. Radiator
13. Oil cooler
14. Fuel filter
15. Accelerator linkage
16. Expansion tank
17. Air cleaner dump valve
MAINTENANCE
5
MAINTENANCE
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 50% - 50% of
water/anti-freeze mixture.
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.
10
MAINTENANCE
6
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.
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