LAND ROVER DEFENDER 1996 Workshop Manual

86ELECTRICAL
16
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
18
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
19
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.

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.