fuse box LAND ROVER DEFENDER 1996 Workshop Manual

12ENGINE
4
REPAIR
14.Disconnect engine harness multi-plug.
15.Remove single bolt securing transmission
breather pipe clip to cylinder head and move
breather pipes aside.
16.Disconnect multi-plug and vacuum pipe from
EGR valve, if fitted.
17.Remove starter motor cover and disconnect
battery and fuse box leads.
18.Remove 3 retaining nuts and disconnect exhaust
down pipe.
19.Disconnect inlet and outlet hoses from power
steering pump.
20.Disconnect bleed hose from thermostat housing.
21.Release bleed hose from retaining clips on front
timing cover plate.
22.Remove split pin securing inner throttle cable to
injector pump lever.
23.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket and move
aside.
24.If fitted, release hand throttle cable from
mounting bracket and injector pump lever and
move aside.
25.Disconnect feed pipe and spill return pipe from
injector pump.

12ENGINE
6
REPAIR 42.Raise engine, and locate front engine mountings
to chassis.
43.Remove gearbox support and lower engine.
44.Tighten front engine mounting to chassis fixings
to
45 Nm (33 lbf/ft).
45.Release chains from engine lifting brackets and
remove hoist.
46.Connect oil cooler pipes to oil filter adaptor.
47.Fit vacuum hose to brake servo adaptor.
48.Secure fuel feed pipe in retaining clip on air
cleaner bracket.
49.Fit fuel lift pump pipes.
50.Connect feed and spill return pipes to injector
pump.
51.If fitted, reconnect hand throttle cable to
mounting bracket and injector pump.
52.Fit outer cable adjusting nut into injector pump
mounting bracket.
53.Fit inner throttle cable to injector pump and
secure with clevis and split pin.
54.Secure bleed hose in retaining clips on front
timing cover.
55.Fit bleed hose to thermostat housing.
56.Connect inlet and outlet hoses to power steering
pump.
57.Fit down pipe to exhaust manifold and secure
with 3 nuts.
58.Connect starter motor battery and fuse box
leads.
59.If fitted, connect EGR valve multi-plug and
vacuum pipe.
60.Secure breather pipe clip to cylinder head.
61.Connect engine harness multi-plug.
62.Fit heater plug feed wire.
63.Connect electrical feed plug at rear of cylinder
head.
64.Fit heater hoses to cylinder head and heater
rails.
65.Fit feed pipe/hose to turbo-charger and
intercooler.
66.Fit rocker cover insulation.
67.Fit radiator assembly.
See COOLING SYSTEM,
Repair, Radiator
If applicable, fit air
conditioning condenser, compressor pipes and
heater matrix hoses.
See AIR CONDITIONING,
Repair, Condenser
68.Fit bonnet.
69.Reconnect battery.CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery.
2.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6.Remove fan cowl.See COOLING SYSTEM,
Repair, Fan cowl
7.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
8.Fit crankshaft pulley retainerLRT-12-080and
secure with 4 bolts.
9.Remove crankshaft pulley retaining bolt
anti-clockwise using socket and suitable long
bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049with thrust pad fromLRT-12-031.

19FUEL SYSTEM
2
DESCRIPTION AND OPERATION A mechanical lift pump, with a hand priming facility, is
driven by the camshaft, and is mounted on the RH
side of the engine.
A fuel filter, with a replaceable element and
incorporating a water separator, is mounted on the
front RH side of the engine compartment.
A fuel sedimentor may be fitted when the vehicle is
operating in more arduous conditions, and is used to
minimise water deposits in the fuel system before
reaching the fuel pump and filter.
Fuel injection is carried out by a Bosch direct injection
pump, incorporating a cold start advance unit and a
high idle setting. The pump is mounted on the RH side
of the engine and is driven directly by gears in the
front cover from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder head. Four
heater plugs, located in the cylinder head directly
below each injector, are fitted to improve cold starting.
An optional hand throttle, for use with a centre power
take off, is located on the fascia to the LH side of the
fuse box, and is linked independently to the fuel
injection pump throttle lever.
Air intake
The air cleaner is mounted on the RH side of the
engine and is connected by hoses to the cold air
intake duct and turbocharger inlet. Fitted between the
air cleaner and turbocharger is the crankcase breather
hose which connects to a breather filter on the rocker
cover.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust down pipe, is
connected by hoses to the air cleaner and an
intercooler which is mounted on the LH side of the
radiator. The intercooler is connected by a hose to the
inlet manifold. When an EGR valve is fitted to the
turbocharger, additional pipes/hoses are used to
connect the components.Exhaust gas recirculation (EGR), when fitted.
Exhaust gas recirculation is controlled by an ECU
mounted under the front centre seat or cubby box and
receives the following inputs:
·Engine temperature from coolant temperature
sender unit on LH side of cylinder head.
·Throttle position from potentiometer on injection
pump.
·Engine speed from speedometer.
When all correct signals are received, the EGR
solenoid allows vacuum to open EGR valve and
recirculate a portion of the exhaust gas. See J6196 for
the EGR system component location and 'Operation'
for full system function.

37MANUAL GEARBOX
2
ADJUSTMENT FIFTH GEAR STOP SCREW - ADJUST
Service repair no - 37.16.67
1.Remove gear lever and transfer box lever knobs.
2.Remove gear lever cover.
3.Remove nut and washer securing gear lever.
4.Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5.Remove insulation pad from tunnel aperture.
6.Remove tunnel carpet.
7.Remove retaining screws and release fuse box
cover.
8.Remove 2 screws and release fuse box from
bulkhead to assist next operation.
9.Remove 16 screws securing tunnel cover to
vehicle body.
10.Manouvre tunnel cover to clear handbrake lever
and remove from vehicle.
11.Fit gear lever and knob and select reverse gear.

MANUAL GEARBOX
3
ADJUSTMENT
12.Slacken stop screw locknut.
13.Apply light pressure to gear lever towards LH
side and turn screw clockwise until it abuts yoke.
14.Turn screw anti-clockwise until 25 mm freeplay
is felt at gear lever knob. Ensure 5th gear can be
engaged.
15.Tighten stop screw locknut.
16.Check that all other gears are selectable.
17.Remove gear lever.
18.Manouvre tunnel cover into position and secure
with 16 screws.
19.Fit fuse box and cover.
20.Fit tunnel carpet.
21.Fit insulation pad into tunnel aperture.
22.Locate gaiter over lower lever and bias springs.
23.Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
24.Fit gear lever cover.
25.Fit gear lever and transfer box lever knobs.

CHASSIS AND BODY
35
REPAIR REV: 05/99
15.If fitted, remove 2 screws, washers and nuts
securing auxiliary switch panel to lower fascia
panel and switch cover.
16.Withdraw switch panel and disconnect switch
leads.
17.Remove 2 screws securing switch cover to
parcel tray.
18.Remove fuse box cover.
19. Models with hand throttle:
Remove fuse box LH retaining screw.
Pivot fuse box down to gain access to lower
inner hand throttle cover fixing screw.
Remove 4 screws and lift up hand throttle cover
from lower fascia panel.
20.Remove 2 screws and remove both footwell
vents from lower fascia panel.
21.Remove single screw and detach door check
strap cover from LH and RH doors.
22.Remove 3 screws securing wiper motor cover to
fascia bulkhead.
23.Release locating pins from fascia panel, lower
wiper motor cover and, if applicable, disconnect
radio speaker leads. Retain wiper motor rack
cover. On LH drive vehicles, disconnect
multi-plugs from rear of switch panel.
24.Prise out 2 large and 5 small cap fasteners
securing trim panel to parcel shelf and fascia
bulkhead.
25.Carefully fold back trim panel to clear fresh air
vent operating levers and remove panel from
parcel shelf.

76CHASSIS AND BODY
36
REPAIRREV: 05/99 26.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
27.Remove parcel shelf.
28.Remove 7 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates.
29.Remove both retaining plates and lower footwell
covers.
30.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
31.With assistance, lower fascia panel and, if
applicable, disconnect RH radio speaker leads.
32.Remove fascia panel from vehicle.Refit
33.Position lower fascia panel to bulkhead,
reconnect RH speaker leads, if applicable, and
secure top edge with 2 bolts.
34.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
35.Repeat operation for LH footwell cover retaining
plate.
36.Fit remaining lower fascia panel fixing screws.
37.Locate parcel shelf. Ensure all radio and
auxiliary switch panel harness leads and plugs
are fed through aperture in parcel shelf.
38.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
39.Fit trim panel and secure with cap fasteners.
40.Reconnect LH speaker leads, if applicable,
locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated. On LH drive
vehicles, reconnect multi-plugs to rear of switch
panel.
41.Secure finisher to wiper motor cover.
42.Fit door check strap covers on both sides.
43.Fit footwell vents to lower fascia panel.
44. Models fitted with hand throttle:
Fit hand throttle cover.
Secure LH side of fuse box.
45.Fit fuse box cover.
46.Fit auxiliary switch cover to parcel tray, if
applicable.

ELECTRICAL
7
DESCRIPTION AND OPERATION ALARM SYSTEM FUSES
When the vehicle immobilisation and alarm system is
fitted, three fuses are used to protect the circuit:
·Alarm system 15 amp fuse, main harness, located
behind instrument binnacle.
·Alarm sounder 20 amp fuse No.10, located in main
fuse box.
·Alarm system 5 amp fuse No.20, located in main
fuse box.
The main fuse box is positioned in the centre of the
fascia, in front of the main gear lever. A label in the
fuse box cover shows the circuits protected, the fuse
rating and their locations. They are also listed below.
MAIN FUSE BOX
Fuse No. Value (amps) Electrical circuit
1 15 Hazard warning lights
2 20 Interior lamp, horn
3 15 Wipers & washers - rear
4 10 Wipers & washers - front
5 15 Heater
6 7.5 Rear fog guard lamps
7 5 Radio/cassette player
8 15 Heated rear window
9 10 Cigar lighter
10 20 Alarm sounder
11 7.5 Headlamp - RH, dipped beam
12 7.5 Headlamp - LH, dipped beam
13 7.5 Headlamp - RH, main beam
14 7.5 Headlamp - LH, main beam
15 5 Side lamps - LH
16 5 Side lamps - RH
17 15 Stop & reverse lamps
18 20 Air conditioning
19 5 Air conditioning
20 5 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.