key battery LAND ROVER DEFENDER 1996 Workshop Manual

12ENGINE
8
REPAIR Refit
14.Fit gasket to centre bolt boss.
15.Locate new gasket and fit front cover plate using
fixing bolts as shown. Tighten bolts to
25 Nm (18
lbf/ft).
1- 25 mm,2- 35 mm,3- 50 mm,4- 100 mm,5- 110
mm
16.Fit crankshaft pulley.
See Crankshaft pulley
17.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
18.Fit fan cowl.See COOLING SYSTEM, Repair,
Fan cowl
19.Fit viscous coupling and fan.See COOLING
SYSTEM, Repair, Viscous coupling and fan
20.Fit intercooler to induction manifold hose.
21.Fit top hose to radiator.
22.Refill cooling system.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
23.Reconnect battery.CAMSHAFT DRIVE BELT
Service repair no - 12.65.18
Remove
1.Remove front cover plate.
See Front cover
plate
2.Position engine at TDC on No. 1 cylinder.
3.Remove blanking plug from flywheel housing
and insert timing toolLRT-12-044.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.

86ELECTRICAL
2
DESCRIPTION AND OPERATION VEHICLE IMMOBILISATION AND ALARM SYSTEM
A sophisticated engine immobilisation and anti-theft
alarm system is offered on the Land Rover Defender
300 Tdi vehicle range, which incorporates the
following features:
Perimeter protection
This part of the alarm system protects side doors,
bonnet and rear door against unauthorised entry -
alarm sounding if any one of these apertures is
opened without alarm first being disarmed.
Interior protection
Also known as volumetric protection, this part of the
system protects space inside the vehicle. Once
armed, the alarm will sound if a door is opened, or if
movement is detected inside the vehicle.
Engine immobilisation
The engine is immobilised electronically whenever the
alarm system is armed. Even if the alarm has not
been armed, engine immobilisation will occur
automatically thirty seconds after the driver's door is
opened, or five minutes after the starter switch is
turned to position '0'.
ALARM SYSTEM COMPONENTS
Electronic control unit (ECU)
The ECU is the alarm system brain and controls all
vehicle immobilisation and alarm functions. It
responds to the inputs received, by supplying suitable
outputs to indicate status of the alarm system or
activating relevant warning devices. unit is located
under fascia behind instrument binnacle.
Handset and key
The handset is the primary source of control for the
alarm system i.e. it arms and disarms the alarm
components. The key can be used to override engine
immoblisation if the handset is lost or fails to operate,
seeEngine immobilisation override.The handset battery should last for approximately
three years dependent upon use. The following
symptoms will be noticed when the battery requires
replacement:
1.The handset will only work every other operation
while disarming.
2.The direction indicator lamps will not flash when
the alarm is disarmed.
For battery replacement procedure, seeHandset
Battery.
Passive coil
The passive coil is fitted on the starter switch and
activates a receiving coil in the handset, causing it to
automatically transmit a remobilisation signal to the
ECU.
Aerial
The aerial is integral within the alarm system harness
and supplies the ECU with the signal received from
handset.
Immobilisation spider
The immobilisation spider provides an interface
between ECU and immobilised areas of the vehicle.
This is installed in a sealed (safe) box inside the
vehicle battery box.
Digital diesel shut-off valve - 97 MY
When fitted, the digital diesel shut-off valve
immobilises the fuel injection pump by preventing
power reaching the fuel shut-off solenoid,
See
Immobilisation and alarm system circuit diagram -
with DDS
.

86ELECTRICAL
4
DESCRIPTION AND OPERATION REV: 05/99 ALARM SYSTEM COMPONENT LOCATION
COMPONENT LOCATION
1. Electronic control unit (ECU) Under dash, LH and RH drive
2. Anti-theft alarm indicator light Instrument panel
3. Engine immobilisation warning light Instrument panel
4. Immobilisation spider* Inside vehicle battery box
5. Passive coil Over starter switch barrel
6. Bonnet switch Engine compartment, LH and RH drive
7. Door switches
8. Ultrasonic sensor Varies according to vehicle type
9. Handset and key
10. Alarm sounder (without battery back-up) LH inner front wing
11. Alarm sounder (with battery back-up) LH inner front wing
* Replaced in some markets by a digital diesel shut-off valve (DDS), secured directly to fuel shut-off solenoid on
injection pump.

ELECTRICAL
9
DESCRIPTION AND OPERATION IMMOBILISATION AND ALARM SYSTEM CIRCUIT
DIAGRAM
1.Anti-theft alarm indicator light (LED)
2.Engine immobilisation warning light
3.Alarm system fuse - 15 amp
4.Alarm sounder relay
5.Under bonnet lighting fuse
6.Alarm sounder (without battery back-up)
7.Alarm system fuse - 5 amp (position 20)
8.Electronic control unit (ECU)
9.Bonnet switch
10.Alarm sounder protection fuse - 20 amp
(position 10)
11.Starter switch
12.Under bonnet ignition fuse
13.Driver's door switch
14.Vehicle horn switch
15.Vehicle horn
16.Passive coil
17.Starter switch relay
18.Front passenger door switch
19.Hazard warning light fuse - 15 amp (position 1)
20.Ultrasonic sensor
21.Interior lamp and horn fuse - 20 amp (position 3)
22.Alarm sounder (with battery back-up)
23.LH direction indicator lamps
24.RH direction indicator lamps
25.Interior lamp
26.Immobilisation spider
27.Rear side doors and rear door switches
28.Diagnostic connector
29.Diagnostic fuse - 7.5 amp
30.Starter solenoid
31.Fuel switch-off solenoid (injection pump)
32.Generator
33.AerialKey to cable colours
B-Black
G-Green
K-Pink
LG-Light Green
N-Brown
O-Orange
P-Purple
R-Red
S-Slate
U-Blue
W-White
Y-Yellow
The last letter of a colour code denotes the tracer
colour

ELECTRICAL
11
DESCRIPTION AND OPERATION IMMOBILISATION AND ALARM SYSTEM CIRCUIT
DIAGRAM - WITH DDS
1.Anti-theft alarm indicator light (LED)
2.Engine immobilisation warning light
3.Alarm system fuse - 15 amp
4.Alarm sounder relay
5.Under bonnet lighting fuse
6.Alarm sounder (without battery back-up)
7.Alarm system fuse - 5 amp (position 20)
8.Electronic control unit (ECU)
9.Bonnet switch
10.Alarm sounder protection fuse - 20 amp
(position 10)
11.Starter switch
12.Under bonnet ignition fuse
13.Driver's door switch
14.Vehicle horn switch
15.Vehicle horn
16.Passive coil
17.Starter switch relay
18.Front passenger door switch
19.Hazard warning light fuse - 15 amp (position 1)
20.Ultrasonic sensor
21.Interior lamp and horn fuse - 20 amp (position 3)
22.Alarm sounder (with battery back-up)
23.LH direction indicator lamps
24.RH direction indicator lamps
25.Interior lamp
26.Digital diesel shut-off valve (DDS)
27.Rear side doors and rear door switches
28.Diagnostic connector
29.Diagnostic fuse - 7.5 amp
30.Starter solenoid
31.Fuel shut-off solenoid (injection pump)
32.Generator
33.AerialKey to cable colours
B-Black
G-Green
K-Pink
LG-Light Green
N-Brown
O-Orange
P-Purple
R-Red
S-Slate
U-Blue
W-White
Y-Yellow
The last letter of a colour code denotes the tracer
colour

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
6
REPAIR IMMOBILISATION SPIDER
Service repair no - 86.77.03
Remove
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Slacken battery lead clamp bolts.
4.Turn starter switch 'on'.
5.Turn starter switch 'off' and remove key.
6.Disconnect battery leads.
NOTE: Operation 6 needs to be carried out
within 15 seconds to avoid activating
battery backed-up alarm sounder, if fitted.
7.Remove battery clamp and 'J' bolts.
8.Remove 4 nuts securing immobilisation spider
housing box to fixing studs on front face of
battery box.
9.Remove grommet securing spider harness to
corner face of battery box.
10.Carefully pull harness into battery box, lift spider
housing box and place on front edge of seat
base.
11.Using a suitable sheet to protect inside of
vehicle, grind heads off 6 monobolts securing lid
to spider box housing.
12.Detach lid from housing and disconnect spider
harness plug.
13.Unscrew two nuts and remove immobilisation
spider from lid studs.
NOTE: If spider box lid and/or sealing
gasket is damaged during operation 11 a
new lid will need to be fitted.
NOTE: A new immobilisation spider must
be initialised using TestBook.
Refit
14.Fit immobilisation spider onto lid studs and
secure with retaining nuts.
15.Reconnect harness plug to spider and ensure it
fully 'clicks' home.
16.Position lid and spider assembly into box
housing so that harness plug is furst away from
harness entry.
17.Secure lid to spider box housing with monobolts.
18.Refit harness grommet into spider box, if
disturbed on removal procedures, and ensure
harness covering is fully inserted through
grommet to make water tight seal.
19.Push excess harnes cable through corner face
of battery box and fit grommet.
20.Fit spider housing box to fixing studs and secure
with four nuts.
21.Fit 'J' bolts and clamp to secure battery,
22.Reconnect battery leads.
23.Fit battery access cover.
24.Fit LH seat cushion.
25.Test immobilisation and alarm system.