ECU LAND ROVER DEFENDER 1996 Workshop Manual

86ELECTRICAL
10
REPAIR Refit
12.Fit alarm indicator light into fascia panel and
reconnect plug lead.
13.Reconnect speedometer cable and fit instrument
panel to fascia cowl.
14.Fit steering wheel
See STEERING, Repair,
Steering wheel.
15.Reconnect battery negative lead.
16.Fit battery access cover.
17.Fit LH seat cushion.ALARM SYSTEM FUSE
Service repair no - 86.77.04
Remove
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Slacken battery negative lead clamp bolt.
4.Turn starter switch 'on'.
5.Turn starter switch 'off' and remove key.
6.Disconnect battery negative lead.
NOTE: Operation 6 needs to be carried out
within 15 seconds to avoid activating
battery backed-up alarm sounder, if fitted.
NOTE: If an alarm sounder without battery
back-up is fitted, it is not necessary to
disconnect battery.
7.Remove steering wheel
See STEERING,
Repair, Steering wheel.
8.Remove 4 screws securing instrument panel to
fascia cowl
See INSTRUMENTS, Repair,
Instrument panel.
9.Pull instrument panel away from fascia and
disconnect speedometer cable, main harness
multi-plugs, alarm LED plug lead, heated rear
screen leads, gearbox oil temperature lead and
immobiliser warning light lead.
10.Remove instrument panel.
11.Remove alarm system 15 amp (blue) fuse from
holder located behind starter switch.

ELECTRICAL
11
REPAIR REV: 05/99 Refit
12.Fit new fuse.
13.Position instrument panel to fascia cowl area
and reconnect immobiliser warning light leads,
gearbox oil temperature lead, heated rear screen
leads, alarm LED plug lead, main harness
multi-plugs and speedometer cable,
14.Secure instrument panel to fascia cowl with 4
screws
See INSTRUMENTS, Repair,
Instrument panel.
15.Fit steering wheelSee STEERING, Repair,
Steering wheel.
16.Reconnect battery negative lead.
17.Fit battery access cover.
18.Fit LH front seat cushion.GENERATOR
Service repair no - 86.10.02
Remove
1.Disconnect battery.
2.Remove drive belt
See Auxiliary drive belt.
3.Unscrew 3 fixings, remove heat shield from rear
of generator, and disconnect electrical leads
from generator.
4.Remove generator bottom fixing bolt.
5.Remove long through bolt from top fixing and lift
generator from engine.
Refit
6.Fit generator to engine mounting bracket and
secure with top and bottom fixing bolts.
7.Connect electrical leads.
8.Fit heat shield.
9.Fit drive belt
See Auxiliary drive belt; Refit.
10.Reconnect battery.

86ELECTRICAL
12
REPAIR AUXILIARY DRIVE BELT
Service repair no - 86.10.03
NOTE: If cast lines on tensioner arm and
tensioner spring case are aligned, a new
drive belt must be fitted.
Remove
1.Disconnect battery.
2.Remove fan cowl
See COOLING SYSTEM,
Repair, Fan cowl.
3.Apply ring spanner to tensioner pulley retaining
bolt.
4.Turn spanner to release pulley tension from belt.
5.Detach belt from pulley.
6.Release tensioner.
7.Complete removal of belt. Mark direction on belt
if refitting.
Refit
8.Using ring spanner, release pulley tensioner and
fit new drive belt.
9.Remove ring spanner, drive belt will
automatically tension.
10.Fit fan cowl
See COOLING SYSTEM, Repair,
Fan cowl.
STARTER MOTOR
Service repair no - 86.60.01
Remove
1.Disconnect battery.
2.Disconnect electrical leads from starter solenoid.
3.Remove 3 fixings securing starter motor to
flywheel housing.
4.Withdraw starter motor.
Refit
5.Locate starter motor and secure to flywheel
housing.
6.Reconnect electrical leads to starter solenoid.
7.Reconnect battery.

86ELECTRICAL
14
REPAIR SIDE, TAIL AND DIRECTION INDICATOR LAMPS
Service repair no - 86.40.34 - Front side lamp
Service repair no - 86.40.45 - Tail lamp
Service repair no - 86.40.42 - Front direction
indicator lamp
Service repair no - 86.40.43 - Rear direction
indicator lamp
Remove
1.Remove 2 screws and withdraw lamp unit.
2.Hold bulb holder and twist lens to release.
3.Push and twist bulb to remove from holder.
Refit
4.Fit new bulb, if necessary.
5.Fit bulb holder to lamp lens.
6.Secure lamp to vehicle.SIDE REPEATER LAMP
Service repair no - 86.40.53.
Remove
1.Push lens firmly to the right.
2.Lift left edge and withdraw lamp unit from wing.
3.Twist bulb holder and release from lens.
4.Pull bulb from holder.
Refit
5.Fit new bulb, if necessary.
6.Fit bulb holder to lens.
7.Locate lamp unit in wing and push firmly to the
left to secure.

ELECTRICAL
15
REPAIR REAR NUMBER PLATE LAMP - BULB RENEWAL
Service repair no - 86.40.85
Remove
1.Remove single screw securing lamp cover and
lens to bulb holder.
2.Remove bulb/s from holder.
Refit
3.Fit new bulb/s.
4.Fit lamp lens and cover.REAR NUMBER PLATE LAMP
Service repair no - 86.40.86
Remove
1.Remove single screw and remove lamp cover
and lens.
2.Uncsrew 2 fixings and remove metal cover to
gain access to lamp fixings and harness leads
inside vehicle.
3.Disconnect lamp leads from harness.
4.Remove 2 bolts, nuts and washers securing
lamp to vehicle body.
5.Remove bulb holder, complete with rubber seal
and mounting plinth.
Refit
6.Feed lamp unit leads through vehicle body and
secure bulb holder, seal and plinth.
7.Fit lamp leads to harness connectors.
8.Fit cover to conceal lamp fixings.
9.Fit lens and lamp cover.

ELECTRICAL
17
REPAIR INTERIOR LAMP - BULB REMOVAL
Service repair no - 86.45.01
Remove
1.Prise lens from lamp unit.
2.Spread bulb holder contacts and release bulb.
Refit
3.Spread bulb holder contacts and fit new bulb.
4.Fit lamp lens.INTERIOR LAMP
Service repair no - 86.45.02
Remove
1.Prise lens cover from lamp unit.
2.Remove 2 nuts securing lamp unit to headlining
and roof mounting bracket.
3.Remove lamp unit from mounting bracket studs
and disconnect harness plug.
4.Remove interior lamp.
Refit
5.Reconnect harness plug and locate lamp unit on
mounting bracket studs. Ensure lamp switch
eyelet is correctly seated on lamp unit base.
6.Secure lamp unit to mounting bracket and fit
lamp lens.

86ELECTRICAL
20
REPAIR WINDSCREEN WIPER/WASHER SWITCH
Service repair no - 84.15.34
Remove
1.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle.
2.Disconnect switch multi-plug from main harness.
3.Remove 2 screws and star washer securing
switch to mounting bracket.
4.Remove switch complete with harness.
Refit
5.Fit new switch to mounting bracket.
6.Reconnect switch multi-plug.
7.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle.
DIRECTION INDICATOR/HEADLAMP/HORN
SWITCH
Service repair no - 86.65.55
Remove
1.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle.
2.Disconnect 3 steering column switch multi-plugs
from main harness.
3.Slacken clamp screw and withdraw switch
assembly from steering column.
4.Remove fixings and detach windscreen
wiper/washer and main lighting switches from
mounting bracket.
5.Renew complete direction
indicator/headlamp/horn switch and switch
bracket assembly.
Refit
6.Fit main lighting and windscreen wiper/washer
switches to mounting bracket.
7.Position switch assembly on steering column
and fully tighten clamp.
8.Reconnect switch multi-plugs.
9.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle.

ELECTRICAL
23
REPAIR HEADLAMP LEVELLING SWITCH
Service repair no - 86.65.16
Remove
1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect multi-plug from rear of headlamp
levelling switch.
3.Remove knob from switch spindle.
4.Unscrew retaining nut and withdraw switch from
switch panel.
Refit
5.Fit switch into switch panel and secure with
retaining nut.
6.Fit switch knob.
7.Connect switch multi-plug.
8.Fit switch panel.HEADLAMP LEVELLING UNIT
Service repair no - 86.41.16
Remove
1.Remove headlamp
See Headlamp.
2.Disconnect headlamp levelling unit harness
plug.
3.Rotate levelling unit anti-clockwise to release
retaining lugs from mounting bracket on
headlamp body.
4.Release levelling unit spindle from retaining slot
on headlamp bezel and withdraw unit from
mounting bracket.
Refit
5.Fit levelling unit into mounting bracket and locate
unit spindle into slot in headlamp bezel.
6.Press in unit and rotate clockwise to engage
retaining lugs behind mounting bracket.
7.Connect levelling unit harness plug.
8.Fit headlamp
See Headlamp.

ELECTRICAL
25
REPAIR DIGITAL DIESEL SHUT-OFF VALVE (DDS)
Service repair no - 86.77.00
Remove
1.Remove fuel injection pump
See FUEL
SYSTEM, Repair, Fuel injection pump.
2.Drill out 2 shear bolts securing DDS valve and
clamp, using a 3.2 mm drill, to a depth of
approximately 5 mm.
CAUTION: Use a drill bushing to guide the
drill.
3.Using an extractor, remove the 2 DDS valve
retaining bolts and discard.
4.Release DDS valve from fuel shut-off solenoid.
5.Remove protective cap from shut-off solenoid.
6.Unscrew terminal nut, release terminal lead
eyelet and remove DDS valve.7.Remove protective cap retainer and release
DDS valve clamp from behind fuel shut-off
solenoid.
Refit
8.Position DDS valve clamp behind fuel shut-off
solenoid and fit protective cap retainer.
9.Fit DDS terminal lead to fuel shut-off solenoid.
Tighten nut to
2 Nm (1.5 lbf/ft).
10.Fit protective cap to fuel shut-off solenoid,
ensuring terminal lead is correcly routed on RH
side of cap.
11.Secure DDS valve to fuel cut-off solenoid and
clamp. Tighten new shear bolts progressively
until heads shear.
12.Fit fuel injection pump
See FUEL SYSTEM,
Repair, Fuel injection pump.

INSTRUMENTS
1
REPAIR INSTRUMENT PANEL
Service repair no - 88.20.02
Remove
1.Disconnect battery.
2.Remove 4 screws securing instrument panel to
fascia cowl.
3.Pull instrument panel away from fascia sufficent
to disconnect speedometer cable.
4.Disconnect multi-plugs, electrical leads and
connections to vehicle alarm system, if fitted
See ELECTRICAL, Repair, Vehicle
immobilisation and alarm system
.
5.Withdraw panel, complete with instruments.
Refit
6.Offer up instrument panel, connect multi-plugs,
electrical leads and connections to vehicle alarm
system, if fitted
See ELECTRICAL, Repair,
Vehicle immobilisation and alarm system
.
7.Connect speedometer cable.
8.Secure instrument panel.
9.Reconnect battery.SPEEDOMETER
Service repair no - 88.30.01
Remove
1.Remove 4 screws securing instrument panel to
fascia cowl.
2.Pull instrument panel away from fascia sufficent
to disconnect speedometer cable.
3.Release both bulb holders from speedometer.
4.Unscrew 2 knurled nuts and remove clamps
securing speedometer.
5.Wihdraw speedometer from instrument panel.
Refit
6.Fit speedometer into instrument panel and
secure with clamps.
7.Fit bulb holders to speedometer.
8.Connect speedometer cable.
9.Secure instrument panel to fascia cowl.