Defender (1999-2002). Manual — part 13
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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
8
MAINTENANCE
FUEL FILTER ELEMENT
1. Renew fuel filter element. See FUEL SYSTEM,
Repair.
FUEL FILTER SEDIMENTER - Td5
WARNING: Fuel vapour is highly
flammable and in contained speces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR
POWDER close at hand when handling or draining
fuel.
1. Disconnect battery negative lead.
2. Position suitable container beneath fuel filter
3. Disconnect multiplug from sedimenter
4. Rotate sedimenter anti-clockwise until water
flows from drain tube.
5. Allow to drain until diesel fuel flows from drain
tube.
6. Rotate sedimenter fully clockwise.
7. Connect multiplug.
8. Reconnect battery negative lead.
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MAINTENANCE
9
MAINTENANCE
INTERCOOLER / COOLING SYSTEM
1. Visually check for any obstructions in the
radiator and intercooler matrix and remove
debris as necessary.
2. Visually check fan blades for damage.
3. Check cooling, intercooler and heating systems
for leaks, hoses and oil pipes for security and
condition.
4. Check accessible hose clips for tightness.
5. Check coolant level, top-up if necessary
Cooling System Top-Up
1. With engine cold, remove expansion tank filler
cap.
2. Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.
3. Fit expansion tank filler cap.
Intercooler Flush
1. Remove intercooler. See FUEL SYSTEM,
Repair.
2. Flush intercooler element using Unicorn
Chemicals ’C’ Solve following the manufaturers
instructions.
3. Thoroughly dry intercooler ensuring that no trace
of solvent remains in the element.
4. Refit intercooler. See FUEL SYSTEM, Repair.
AMBIENT AIR PRESSURE (AAP) SENSOR - Td5
1. Check ambient air pressure sensor for damage.
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MAINTENANCE
10
MAINTENANCE
DOOR LOCKS AND HINGES
Front, rear and tail doors
1. Open each door in turn and lubricate door
hinges and check strap using recommended
lubricant.
2. Lubricate door lock, striker and private lock using
PTFE lubricant. Remove excessive lubricant,
particularly from door striker area, to avoid
customer complaint.
3. Check tightness of accessible door lock and
striker fixings
4. Open and close door to check for smooth,
noise-free operation. Ensure door closes
securely.
5. Check for smooth operation of private lock.
Bonnet
1. With bonnet open, lubricate hinges, striker, lock
and safety catch using a suitable lubricant.
ENGINE COOLANT
1. Renew engine coolant. See COOLING
SYSTEM, Adjustment.
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