service LAND ROVER DEFENDER 1996 Workshop Manual

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
21
REPAIR MAIN LIGHT SWITCH
Service repair no - 86.65.10
Remove
1.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle.
2.Disconnect main light switch multi-plug from
main harness.
3.Slacken locknut and release light switch from
slot in mounting bracket.
Refit
4.Fit light switch in mounting bracket.
5.Reconnect switch multi-plug.
6.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle.
HEATED REAR SCREEN, REAR FOG LAMP AND
HAZARD WARNING SWITCHES
Service repair no - 86.65.36 - Heated rear screen
Service repair no - 86.65.65 - Rear fog lamp
Service repair no - 86.65.50 - Hazard warning
Remove
1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect multi-plug from rear of switch.
3.On hazard warning switch only, remove 2
separate leads.
4.Press in spring retainers and withdraw switch
from switch panel.
Refit
5.Fit new switch into switch panel.
6.Reconnect switch multi-plug, and leads if
applicable.
7.Fit switch panel to lower fascia.

86ELECTRICAL
22
REPAIR CIGAR LIGHTER
Service repair no - 86.65.60
Remove
1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect electrical leads from switch housing,
including illumination bulb.
3.Release 2 retaining tags and remove bulb holder
from switch housing.
4.Remove cigar lighter from switch housing.
5.Press in retaining tags and withdraw housing
from switch panel.
Refit
6.Fit housing to switch panel.
7.Fit bulb holder to switch housing.
8.Connect electrical leads and illumination bulb.
9.Insert cigar lighter into switch housing.
10.Fit switch panel to lower fascia.REAR SCREEN WIPER/WASHER SWITCH
Service repair no - 84.35.34
Remove1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect electrical leads from rear screen
wiper/washer switch.
3.Insert a small screwdriver in base of switch
knob, press in retaining lug, and remove knob
from switch spindle.
4.Unscrew locking ring, with wavy washer, and
withdraw wiper/washer switch from panel.
Refit
5.Fit switch to switch panel.
6.Press in retaining lug and fit knob onto switch
spindle.
7.Connect electrical leads to switch.
8.Fit switch panel.

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.

86ELECTRICAL
24
REPAIRREV: 05/99 HEADLAMP BEAM ALIGNMENT
Service repair no - 86.40.17
Check
Check main beam alignment using beam setting
equipment. Should this not be available the beam can
be temporarily checked and adjusted as follows:-
1.Position vehicle, unladen, on level ground with
tyres correctly inflated, approximately 4 metres
from a wall or screen, marked as illustrated
below.
2.The beam centres 'A' are measured horizontally
on the vehicle and dimension 'B' vertically from
the ground.
3.Switch on main beam and adjust setting, as
necessary, with trimmer screws.On vehicles fitted with headlamp levelling units, check
and adjust headlamp beam alignment as previously
described, with fascia mounted levelling switch at
position '0'. The headlamps can then be adjusted,
according to load conditions, as follows:-
Position '0' - Driver only, or driver and all front seats
occupied (loadspace empty).
Position '1' - All seats occupied (loadspace empty).
Position '2' - All seats occupied by adults and
loadspace loaded to maximum rear axle weight.
Position '3' - Driver only with loadspace loaded to
maximum rear axle weight.

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.

88INSTRUMENTS
2
REPAIR FUEL AND TEMPERATURE GAUGE
Service repair no - 88.25.26 - Fuel gauge
Service repair no - 88.25.14 - Temperature gauge
Remove
1.Remove instrument panel
See Instrument
panel
.
2.Release illumination bulb holder and disconnect
electrical leads from gauge.
3.Unscrew knurled nut and remove clamp
securing gauge.
4.Remove earth lead eylet from gauge stud.
5.Withdraw gauge from instrument panel
Refit
6.Fit gauge into instrument panel, locate earth
lead, and secure with clamp.
7.Fit bulb holder and electrical leads.
8.Fit instrument panel
See Instrument panel.CLOCK - FASCIA PANEL
Service repair no - 88.15.07
Remove
1.Remove 4 screws securing instrument panel to
fascia cowl.
2.Pull panel away fom fascia sufficient to
disconnect speedometer cable.
3.Disconnect electrical leads and bulb holder from
clock.
4.Unscrew knurled nut and remove clamp
securing clock.
5.Remove clock from instrument panel.
Refit
6.Fit clock into instrument panel and secure with
clamp.
7.Fit bulb holder and electrical leads.
8.Connect speedometer cable.
9.Secure instrument panel to fascia cowl.

INSTRUMENTS
3
REPAIR CLOCK - CENTRE DASH PANEL
Service repair no - 88.15.07
Remove
1.Remove 2 screws and withdraw switch panel
from centre dash.
2.Release illumination bulb holder and disconnect
electrical leads from clock.
3.Press in spring retainers and remove clock from
panel.
Refit
4.Fit clock into dash panel.
5.Fit electrical leads and bulb holder.
6.Secure switch panel to centre dash.WARNING LIGHT PANEL
Service repair no - 88.20.18
Remove
1.Remove 2 screws and withdraw warning light
panel.
2.Disconect both multi-plugs.
3.Disconnect illumination bulb leads.
4.Remove warning light panel.
Refit
5.Fit illumination bulb leads and multi-plugs to
warning light panel.
6.Secure warning light panel to instrument panel.

88INSTRUMENTS
4
REPAIR PRINTED CIRCUIT - WARNING LIGHT PANEL
Service repair no - 88.20.20
Remove
1.Remove warning light panel
See Warning light
panel
.
2.Remove 13 illumination bulb holders from light
panel.
3.Release printed circuit from locating pins and
remove from panel seatings.
Refit
4.Fit new printed circuit over panel seatings and
position on locating pins.
5.Fit illumination bulbs to secure circuit.
6.Fit warning light panel
See Warning light
panel
.FUEL GAUGE TANK UNIT - REAR FUEL TANK,
110/130
Service repair no - 88.25.30
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out the following instructions.
Remove
1.Disconnect battery.
2.Remove fuel filler cap.
3.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
4.On LH side of tank, disconnect fuel supply pipe
from outlet pipe on fuel gauge unit.
5.Disconnect electrical plug from fuel gauge unit.
6.Release locking ring and withdraw fuel gauge
unit from tank, complete with sealing ring.
Refit
7.Insert gauge unit into tank with float positioned to
base of tank. Fit new sealing washer, if
necessary.
8.Secure gauge unit with locking ring.
9.Fit electrical plug and reconnect fuel supply pipe.
10.Refill fuel tank.
11.Reconnect battery.