instrument panel LAND ROVER DEFENDER 1996 Workshop Manual

04GENERAL SPECIFICATION DATA
8
INFORMATION Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W bayonet
Side repeater lamps 12V 5W capless
Tail lamps 12V 5/21W bayonet
Direction indicator lamps 12V 21W bayonet
Number plate lamp 12V 5W capless
Reverse lamp 12V 21W bayonet
Rear fog guard lamp 12V 21W bayonet
Interior roof lamps 12V 10W festoon
Instrument illumination 12V 1.2W capless
Warning light panel 12V 1.2W bulb/holder unit
Hazard warning switch 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

STEERING
1
REPAIR STEERING COLUMN
Service repair no - 57.40.01
Remove
1.Remove bonnet.
2.Set road wheels and steering wheel in straight
ahead position.
3.Mark relationship of steering column inner shaft
to top universal joint.
NOTE: collapsible shaft can be
disconnected from steering column only, if
required, by removing bolts from top
universal joint and slackening top bolt of lower
universal joint.
4.Remove 2 bolts from top universal joint and
lower bolt of bottom universal joint. Slacken top
bolt of lower universal joint and withdraw shaft.5.Prise centre cap from steering wheel.
6.Remove steering wheel retaining nut and
withdraw wheel from column spline.
7.Disconnect battery.
8.Remove 4 screws securing instrument panel and
pull panel away from facia to enable
speedometer cable to be disconnected.
9.Disconnect multi-plugs, electrical leads and
connections to vehicle alarm system, if fitted.
See ELECTRICAL, Repair, Vehicle
immobilisation and alarm system
.
10.Withdraw panel complete with instruments.
11.Remove 5 screws and 2 self-tapping screws to
remove top half of nacelle.
12.Ease bottom half of nacelle from switch
gaiters/grommets and remove.

57STEERING
2
REPAIR
13.Disconnect 3 switch multi-plugs.
14.Slacken clamp screw on top of switch cluster
and withdraw switch assembly.
15.Note position of harness leads on back of starter
switch and disconnect lucars. If fitted, remove
alarm system passive coil from switch
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
16.Using a punch or stud extractor remove 2 shear
bolts securing switch to column.
17.Remove switch and collect 2 plain washers
between switch and clamp.
18.Remove brake pedal box
See BRAKES,
Repair, Brake pedal
.
19.Remove bolt securing tie-bar to steering column,
behind instrument panel.
20.Remove 2 bolts securing column lower support
to mounting bracket.
21.Remove bolts securing two halves of top clamp
and bolts that secure top half of clamp to
bulkhead.
22.Remove clamp and rubber packing.
23.Remove 2 bolts securing column main support
bracket to bulkhead.
24.Remove steering column and main support
bracket from vehicle.

STEERING
3
REPAIR REV: 05/99
NOTE: The steering column is a non
serviceable component and can only be
serviced as a complete assembly.
25.Fit main support bracket and padding to steering
column and manoeuvre column into position in
vehicle.
26.Loosely secure main support bracket and
harness bracket to bulkhead.
27.Loosely fit clamp and rubber packing strip to
column.
28.Loosely secure lower end of column to lower
support bracket.
29.Loosely secure clamp bracket to main support
bracket.
30.Working inside vehicle cab, fit tie-bar to column
bracket and secure with single bolt to
22 Nm (16
lbf/ft).
31.Finally, tighten main support bracket, clamp
bracket, upper clamp, and lower support bracket
nuts and bolts. (M6 bolts
9 Nm (6 lbf/ft),M8
bolts
22 Nm (16 lbf/ft).
32.Fit brake pedal boxSee BRAKES, Repair,
Brake pedal
.
33.Fit steering lock/switch in position and rotate
steering column inner shaft to line up slot with
switch plunger.
34.Secure lock to column with clamp and shear
bolts. Evenly tighten bolts but do not shear them.
35.Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly.
36.Fully tighten switch retaining bolts until heads
shear.
37.Connect electrical leads to rear of switch. Fit
alarm system passive coil, if applicable.
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
38.Fit switch assembly on steering column and
tighten clamping screw.
39.Connect switch assembly multi-plugs and
electrical leads to main harness.
40.Offer up instrument panel, connect speedometer
cable, multi-plugs and electrical leads to main
harness. If applicable, fit vehicle alarm system
connections.
See ELECTRICAL, Repair,
Vehicle immobilisation and alarm system
.
41.Secure panel with 4 screws.
42.Locate top half of nacelle in position and fit to
switch gaiters/grommets.43.Fit lower half of nacelle and loosely tighten fixing
screws.
44.Ensure switch gaiters/grommets are correctly
located and fully tighten fixings.
45.Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left, in
direction of indicator switch.
46.Fit steering wheel with finisher attachment lug at
bottom, ensuring that indicator cancelling forks
locate in cancelling ring slots.
47.Secure wheel with nut and new shake-proof
washer. Tighten to
43 Nm (32 lbf/ft).
48.Fit steering wheel decal.
49.If necessary, fit new universal joints to support.
Note that long joint is fitted to short length of
shaft and short joint to long end. Joints can only
be fitted one way to shaft.
50.With steering lock engaged and road wheels in
straight ahead position, align reassembly marks,
and fit collapsible shaft assembly with long leg of
shaft to steering box. Fit pinch bolts and tighten
to
25 Nm (18 lbf/ft).

STEERING
9
REPAIR REV: 05/99 STEERING COLUMN LOCK
Service repair no - 57.40.28
Remove
1.Disconnect battery.
2.Set road wheels in straight ahead position.
3.Remove steering wheel
See Steering wheel.
4.Remove instrument panel
See INSTRUMENTS,
Repair, Instrument panel
.
5.Remove steering column nacelle
See Steering
column nacelle
.
6.Note position of harness leads on back of starter
switch and disconnect lucars. If fitted, remove
alarm system passive coil from switch
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
7.Using a punch or stud extractor remove 2 shear
bolts securing steering lock/starter switch to
column.
8.Remove steering lock and collect 2 washers
between lock and clamp.
Refit
9.Fit steering lock/switch in position and line up
with switch plunger.
10.Secure lock to column with clamp and new shear
bolts. Evenly tighten bolts but do not shear them.
11.Temporarily fit steering wheel and operate lock
and switch mechanism to ensure it functions
correctly.
12.Fully tighten retaining bolts until heads shear.
13.Connect harness leads to rear of starter switch.
If applicable, fit alarm system passive coil
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.14.Fit steering column nacelle
See Steering
column nacelle
.
15.Fit instrument panel
See INSTRUMENTS,
Repair, Instrument panel
.
16.Fit steering wheel
See Steering wheel.
17.Reconnect battery.

76CHASSIS AND BODY
34
REPAIRREV: 05/99 LOWER FASCIA PANEL (HEATER DUCT)
ASSEMBLY
Service repair no - 76.46.05
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel
.
3.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle
.
4.Remove instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
5.Release heater cable at control lever
See
HEATING AND VENTILATION, Repair, Heater
control cable - air distribution
.
6.Remove 2 screws, withdraw switch panel from
lower fascia and disconnect switch multi-plugs.
7.Prise out Land Rover decal and remove screw
securing grab handle to crash pad.
8.Remove lower screw and lift grab handle from
lower fascia panel.
9.On RH drive vehicles only, remove screw
securing LH side of finisher to wiper motor cover.
10.Remove 4 screws and remove both demister
vents from crash pad.
11.Remove 3 screws securing crash pad to fascia
bulkhead.
12.Remove crash pad.
13.Remove radio, if fitted.
14.Remove 2 trim studs securing radio housing to
trim panel. Remove radio housing.

CHASSIS AND BODY
37
REPAIR REV: 05/9947.Connect leads and plugs to auxiliary switches
and clock.
48.Secure switch panel to lower fascia panel and
switch cover.
49.Position radio housing, if applicable, and feed
radio multi- plug, aerial and speaker leads from
switch cover to radio housing.
50.Secure radio housing to trim panel.
51.Fit radio connections and secure radio in
housing.
52.Fit crash pad to fascia bulkhead.
53.Fit demister vents in crash pad.
54.Fit grab handle to lower fascia panel and secure
to crash pad. Refit Land Rover decal.
55.Connect multi-plugs to rear screen, hazard and
interior lamp switches and fit switch panel to
fascia panel.
56.Fit heater control cable
See HEATING AND
VENTILATION, Repair, Heater control cable -
air distribution
.
57.Fit instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
58.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle
.
59.Fit steering wheel
See STEERING, Repair,
Steering wheel
.
60.Reconnect battery.FRONT UNDERTRAY
Service repair no - 76.11.81 - Front undertray
Service repair no - 76.11.85 - Acoustic pad
Remove
1.Raise vehicle on ramp.
2.Position support under chassis front
crossmember.
3.Lower ramp to give clearance between axle and
undertray.
4.Remove 4 nuts, disconnect propeller shaft from
front axle, and move aside.
5.Remove 2 bolts securing undertray to chassis
front crossmember.
6.Remove nut securing undertray to bump stop
front fixing bolt on both sides.
7.Remove 2 bolts securing sides of undertray to
rear undertray.
8.Pull front undertray forwards to release flanges
from rear undertray.
9.Lower undertray to clear steering box etc. and
manouvre rearwards over axle.
10.Remove front undertray.
11.If necessary, remove 8 fasteners to release
acoustic pad from undertray.

80HEATING AND VENTILATION
4
REPAIR HEATER CONTROL CABLE - TEMPERATURE
CONTROL
Service repair no - 80.10.05
Remove
1.Disconnect battery.
2.Remove 4 screws securing instrument panel to
fascia cowl.
3.Pull instrument panel away from fascia and
disconnect speedometer cable to give easier
access to control cable at bulkhead.
4.Remove retaining screws and pull off air
distribution and temperature control lever knobs.
5.Remove 3 screws and detach side cover,
complete with control lever assembly.
6.Remove 2 screws securing control lever
assembly to side cover and remove cover. Note
plastic screw spacers fitted between cover and
control lever assembly and retain.
7.Remove small bolt and release outer cable
retaining clip.
8.Slacken grub screw and release inner cable from
clevis.
9.From inside engine compartment, release outer
cable retaining clip at heater unit.
10.Slacken trunnion fixing and release inner cable
from heater unit flap lever.
11.Release 2 retaining clips securing control cables
to engine bulkhead and heater hoses.
12.Pull control cable through bulkhead grommet
and remove from vehicle.
Refit
13.Fit new control cable to heater flap lever trunnion
with approximately 10 mm of inner cable
protruding from trunnion. Fully tighten trunnion.
14.Secure outer cable with retaining clip.
15.Route control cable through sealing grommet
and along inside of engine bulkhead to fascia
panel.

HEATING AND VENTILATION
5
REPAIR 16.Secure control cables to engine bulkhead and
heater hoses with retaining clips.
17.With control lever in closed position, fit inner
cable to lever clevis and fully tighten clevis grub
screw.
18.Fit outer cable retaining clip and fully tighten
securing bolt.
19.Fit side cover to control lever assembly. Ensure
fixing screw spacers are positioned between
cover and lever assembly.
20.Fit side cover to fascia.
21.Fit control lever knobs.
22.Reconnect speedometer cable and fit instrument
panel.
23.Reconnect battery.

80HEATING AND VENTILATION
6
REPAIR HEATER CONTROL CABLE - AIR DISTRIBUTION
Service repair no - 80.10.12
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel.
3.Remove steering column nacelleSee
STEERING, Repair, Steering column nacelle.
4.Remove instrument panelSee INSTRUMENTS,
Repair, Instrument panel.
5.Remove retaining screws and pull off air
distribution and temperature control lever knobs.
6.Remove 3 screws and detach side cover,
complete with control lever assembly.
7.Remove 2 screws securing control lever
assembly to side cover and remove cover. Note
plastic screw spacers fitted between cover and
control lever assembly and retain.
8.Remove small bolt and release outer cable
retaining clip.
9.Slacken grub screw and release inner cable from
clevis.
10.Remove lower fascia panel assembly
See
CHASSIS AND BODY, Repair, Lower fascia
panel (heater duct) assembly.
11.Remove 19 screws and lift off heater duct cover.
12.Slacken vent flap trunnion fixing, release air
distribution control cable and remove from
heater duct.
13.Check condition of foam sealant on heater duct
cover and renew if necessary.