service 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
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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.

ELECTRICAL
13
REPAIR HEADLAMP
Service repair no - 86.40.02
Remove
1.Remove screws retaining side and direction
indicator lamps.
2.Withdraw lamp units and disconnect plugs.
3.Remove 2 screws and withdraw headlamp
finisher.
4.Remove 2 headlamp retaining screws.
5.Rotate headlamp clockwise, disengage from
body, and lift out headlamp.
6.Disconnect multi-plug to release headlamp. On
vehicles fitted with headlamp levelling unit, also
release unit harness plug
See Headlamp
levelling unit.
7.Remove rubber cover.
8.Release spring clip and withdraw headlamp
bulb.
NOTE: Do not touch bulb glass with
fingers. If necessary, clean bulb with
methylated spirits.Refit
9.Fit bulb to headlamp and retain with spring clip.
10.Fit rubber cover and reconnect multi-plug. If
applicable, fit headlamp levelling unit plug
See
Headlamp levelling unit.
11.Locate headlamp in body and rotate
anti-clockwise to engage.
12.Fit headlamp retaining screws.
13.Fit headlamp finisher, side and direction
indicator lamps.
14.Check main beam alignment
See Headlamp
beam alignment.

86ELECTRICAL
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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.

86ELECTRICAL
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REPAIR REVERSE AND FOG GUARD LAMP - BULB
RENEWAL
Service repair no - 86.40.90
Remove
1.Remove two screws with sealing washers and
remove lens from lamp body.
2.Push and twist bulb to release from holder.
3.Clean interior of lamp and lens.
Refit
4.Fit new bulb.
5.Fit lens to lamp body.REVERSE AND FOG GUARD LAMP
Service repair no - 86.40.91 - Reverse lamp
Service repair no - 86.40.99 - Fog guard lamp
Remove1.From underneath the vehicle, lift protective flap
and disconnect lamp leads at harness
connectors.
2.Unscrew 2 nuts and washers and withdraw lamp
unit from vehicle.
Refit
3.Feed lamp leads through grommet and locate
lamp studs in vehicle body.
4.Fit retaining nuts and reconnect lamp leads to
vehicle harness.

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
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REPAIR REVERSE LAMP SWITCH
Service repair no - 37.27.01
Remove
The reverse lamp switch is located on the LH side of
the gearbox extension housing and is accessible from
underneath the vehicle.
1.Place vehicle on suitable ramp.
2.Disconnect reverse lamp switch lead multi-plug
from harness connector.
3.Unscrew switch from extension housing.
Refit
4.Fit new switch to gearbox extension housing.
Tighten to
25 Nm (18 lbf/ft).
5.Fit lamp switch lead multi-plug to harness
connector.
6.Check operation of lamp switch.WARNING LAMP ASSEMBLY
Service repair no - 86.45.60 - Warning lamp
assembly
Service repair no - 86.45.61 - Warning lamp bulb
renewal
Remove
1.Disconnect battery.
2.Remove 2 screws and withdraw warning light
assembly from instrument panel.
3.Remove multi-plug to give access to warning
lamp bulbs.
4.Twist bulb holder and pull it from its socket.
5.Pull bulb from holder.
Refit
6.Fit new bulb and refit holder.
7.Fit multi-plug.
8.Fit warning lamp assembly to instrument panel
9.Reconnect battery.

ELECTRICAL
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REPAIR INSTRUMENT ILLUMINATION - BULB RENEWAL
Service repair no - 86.45.49 - Speedometer
Service repair no - 86.45.51 - Temperature gauge
Service repair no - 86.45.52 - Fuel gauge
Remove
1.Disconnect battery.
2.Remove 4 screws retaining instrument panel.
3.Ease panel forward and disconnect
speedometer cable to improve access to
illumination bulbs.
4.Twist bulb holder and pull from socket.
5.Pull bulb from holder.
Refit
6.Fit new bulb and refit holder.
7.Reconnect speedometer cable and fit instrument
panel.
8.Reconnect battery.STARTER SWITCH
Service repair no - 86.65.03
Remove
1.Remove instrument panel
See INSTRUMENTS,
Repair, Instrument panel.
2.Remove steering column nacelleSee
STEERING, Repair, Steering column nacelle.
3.Note position of harness leads on back of starter
switch and disconnect lukars. If fitted, remove
alarm system passive coil from switch
See
Passive coil.
4.Remove single screw and withdraw starter
switch from steering column lock.
Refit
5.Fit new switch in steering column lock.
6.Connect harness leads to starter switch.
7.If applicable, fit alarm system passive coil
See
Passive coil.
8.Fit steering column nacelleSee STEERING,
Repair, Steering column nacelle.
9.Fit instrument panelSee INSTRUMENTS,
Repair, Instrument panel.