warning LAND ROVER DEFENDER 1996 Repair Manual

86ELECTRICAL
2
REPAIR BATTERY
Service repair no - 86.15.01
NOTE: If the vehicle is fitted with a battery
backed-up alarm sounder, disconnecting
the vehicle battery will cause the alarm to
sound unless the following procedure is followed:
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 WITHIN 15 SECONDS.
If alarm is accidentally activated, ensure sounder is
connected and silence by turning the starter switch to
position 'II'.Remove
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect negative lead first. If positive
lead is disconnected with negative lead in place,
accidental contact of a wrench to any grounded
metal part could cause a severe spark, possibly
resulting in personal injury. Upon installation of
battery always connect positive lead first.
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Disconnect both battery leads, negative first.
4.Slacken securing nuts and move battery clamp,
with 'J' bolts aside.
5.Remove battery.
NOTE: Coat battery clamps and terminals
with petroleum jelly before refitting.
Refit
6.Position battery and secure with clamp. Ensure
'J' bolts are hooked correctly under retaining
brackets on base of battery box.
7.Reconnect battery leads, positive lead first.
8.Fit battery access cover.
9.Fit seat cushion.

ELECTRICAL
3
REPAIR ELECTRONIC CONTROL UNIT (ECU)
Service repair no - 86.55.85
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.
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 cowl and
disconnect speedometer cable, multi-plugs,
alarm LED plug lead, heated rear screen lead,
gearbox oil temperature lead and immobiliser
warning light leads.
10.Remove instrument panel.
11.Remove 2 screws securing ECU to fascia cowl
(LH drive shown). On RH drive vehicles ECU is
positioned lower down, on vertical face of fascia
panel.
12.Release ECU from fascia cowl and disconnect
both multi-plugs.
13.Remove ECU.
NOTE: A new ECU must be initialised
using TestBook.
Refit
14.Position ECU at fascia cowl and reconnect both
multi-plugs.
15.Locate ECU on mounting face of fascia cowl and
secure with 2 screws.
16.Position instrument panel to fascia cowl and
reconnect immobiliser warning light leads,
gearbox oil temperature lead, heated rear screen
lead, alarm LED plug lead, multi-plugs and
speedometer cable.
17.Secure instrument panel to fascia cowl with 4
screws
See INSTRUMENTS, Repair,
Instrument panel.
18.Fit steering wheelSee STEERING, Repair,
Steering wheel.
19.Reconnect battery negative lead.
20.Fit battery access cover.
21.Fit LH seat cushion.

86ELECTRICAL
4
REPAIR HANDSET BATTERY
Service repair no - 86.77.13
Remove
1.Unlock vehicle and disarm alarm system.
2.Turn starter switch to position 'II'.
3.Turn starter switch back to position '0' and
remove key.
4.Carefully prise handset apart, starting from
keyring end, using a coin or small screwdriver.
5.Slide battery out from retaining clip.
6.Press and hold one of the handset buttons for at
least five seconds to drain any residual power
from handset.
NOTE: The engine will immobilise five
minutes after key is removed from starter
switch.Refit
7.Fit new battery into handset retaining clip with
positive side uppermost. Finger marks will
adversely affect battery life; if possible, avoid
touching flat surfaces of battery and wipe clean
before fitting.
8.Reassemble two halves of handset.
9.Press RH (Padlock) button at least four times
within range of vehicle to resynchronise handset.
10.Check operation of alarm system.
WARNING: The handset contains delicate
electronic circuits and must be protected
from impact and water damage, high
temperatures and humidity, direct sunlight and
effects of solvents, waxes and abrasive cleaners.
NOTE: New handsets must be be
initialised using TestBook.

ELECTRICAL
5
REPAIR PASSIVE COIL
Service repair no - 86.77.35
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.
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, multi-plugs,
alarm LED plug lead, heated rear screen lead,
gearbox oil temperature lead and immobiliser
warning light leads.
10.Remove instrument panel.
11.Remove 7 screws securing upper and lower
halves of nacelle to steering column mounting
bracket
See STEERING, Repair, Steering
column nacelle.
12.Release multi-switch gaiters from both sides of
nacelle.
13.Remove nacelle upper and lower halves from
steering column; collect blanking grommet from
RH side.
14.Disconnect multi-plug and remove passive coil
from starter switch.
Refit
15.Feed passive coil plug lead into fascia cowl area
and reconnect multi-plug .
16.Fit coil on starter switch.
17.Position nacelle upper and lower halves to
steering column mounting bracket and secure
with 7 screws. Do not fully tighten screws at this
stage
See STEERING, Repair, Steering
column nacelle.
18.Check that passive coil is still fitted correctly on
starter switch.
19.Check fit of nacelle at starter switch and steering
column and fully tighten fixing screws.
20.Fit multi-switch gaiters to both sides of nacelle
and check that blanking grommet is located.
21.Position instrument panel to fascia cowl area
and reconnect immobiliser warning light leads,
gearbox oil temperature lead, heated rear screen
lead, alarm LED plug lead, main harness multi-
plugs and speedometer.
22.Secure instrument panel to fascia cowl with 4
screws
See INSTRUMENTS, Repair,
Instrument panel.
23.Fit steering wheelSee STEERING, Repair,
Steering wheel.
24.Reconnect battery negative lead.
25.Fit battery access cover.
26.Fit LH seat cushion.
27.Test immobilisation and alarm system.

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
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
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.

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.