warning light LAND ROVER DEFENDER 1996 Workshop Manual

01INTRODUCTION
8
INFORMATION JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected, connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to positive
(+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.
D.Connect other end of second jumper cable to a
good earth point on the disabled vehicle (eg. engine
front lifting eye, as shown in J6086),NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners' Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalyst, if fitted.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.

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.

FUEL SYSTEM
9
DESCRIPTION AND OPERATION OPERATION
Diesel engines operate by compression ignition. The
rapid compression of air in the cylinder during the
compression cycle heats the air and when fuel is
injected into the heated air, it ignites instantaneously.
During cold tarting, automatically controlled heater
plugs assist in raising the temperature of the
compressed air to ignition point.
A cold start advance unit advances the injection timing
to further assist starting. Idle quality is improved by
the high idle setting.
The engine is supplied with pre-compressed air by a
single stage turbocharger.
Exhaust gases passing over a turbine cause it to
rotate, driving a compressor mounted on the turbine
shaft. Air drawn from the cold air intake passes, via
the air cleaner, to the turbocharger where it is
compressed. Compression in the turbocharger warms
up the air considerably, so that it expands. As a result
the air mass per cylinder is reduced, having a
negative effect on power output. By fitting a charge-air
intercooler, located on the LH side of the radiator, the
air is cooled before reaching the cylinders. This
increases power output through increased mass of
oxygen in the combustion process, as well as
maximising engine durability, through maintaining
lower piston and head temperatures.
Fuel is drawn from the tank by a mechanical lift pump
and passes to the injection pump via a filter. In
addition to removing particle contamination from the
fuel, the filter incorporates a water separator, which
removes and stores water.
The sedimentor/s, when fitted, is located adjacent to
the fuel tank/s and separates contamination and water
particles in the fuel before reaching the fuel lift pump.
The injection pump meters a precisely timed, exact
quantity of fuel to the injectors in response to throttle
variations, injection timing varying with engine speed.
Any excess fuel delivered to the injection pump is
passed back to the tank via the spill return line.
Fuel is injected in a finely atomised form into the main
combustion chamber, the burning fuel expands
rapidly, creating extreme turbulence which mixes the
burning fuel thoroughly with the compressed air,
providing complete combustion.Cold Starting is assisted by heater plugs, a cold start
advance unit and a high idle setting.
Heater plugs
Heater plug operation is controlled by a timer unit,
start relay and resistor. When the ignition is turned on
the timer unit is energised, the heater plugs start to
operate and a warning light on the dashboard
illuminates, remaining on until the heater plugs are
automatically switched off.
The length of time the heater plugs will operate is
dependent on under bonnet temperature, which is
monitored by a sensor located in the timer unit.
Starting the engine results in the power supply to the
heater plugs passing through the resistor, which
reduces their operating temperature. The heater plugs
are cut out either by the temperature sensor in the
timer, or by a microswitch on the injection pump which
operates when the throttle is depressed.
Cold start advance
The cold start advance unit is connected to the engine
cooling system via hoses. It contains a temperature
sensitive element which is retracted when cold and
pulls the advance lever, via cable, towards the rear of
the pump against spring pressure. As coolant
temperature rises, the cold start element expands
releasing tension on the cable and allowing spring
pressure to move the advance lever forwards.
Exhaust gas recirculation (EGR), when fitted
Operation of the EGR system is dependent on the
following:
·Engine temperature - must be between 20°C and
100°C approx.
·Engine speed - must be between 630 and 2850
rev/min.
·Engine load - calculated by throttle position
sensor.
·EGR valve lift position.
·Duration of engine idling.

STEERING
5
FAULT DIAGNOSIS REV: 05/99 Symptom :-
Steering excessively light/sensitive. Excessive
freeplay at steering wheel.
1.Are steering box adjustments correct?
NO -
See Adjustment, Power Steering Box.
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is within warranty, it must be
returned to manufacturer. No attempt must be
made to introduce backlash.
YES - Suspect worn panhard rod or radius arm
bushes. Check condition of ball joints and the
lower steering column shaft universal joints for
wear
See Repair, Lower Steering Shaft and
Universal Joints
.
Symptom :-
Steering vibration, road wheel shimmy - wobble.
Vibration through the steering linkage powerful
enough to induce high frequency oscillation of the
steering wheel, is generally caused by out of balance
road wheels. However there are a number of other
possible causes of this symptom which if severe, may
be described as shimmy or wobble. Regardless of the
terminology used by the owner/driver to describe the
symptoms, the following diagnostic checks should be
carried out in the order presented.
1.Check the tyres and balance of the road wheels
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres
,See
WHEELS AND TYRES, Fault diagnosis, Fault
- Symptoms See WHEELS AND TYRES,
Repair, Wheel Balancing .
2.Check the steering hydraulic damper function
See Steering Damper.
3.Check steering column universal joints for wear
and correct alignment
See Repair, Lower
Steering Shaft and Universal Joints
.4.Check steering linkage ball joints for wear,
correct alignment and security, including steering
box and tie rod
See Steering Linkage Inspect
.
5.Check all front suspension rubbers for wear.
Check all fixing torques, including radius arm
bushes, panhard rod and anti-roll bar
See
FRONT SUSPENSION, Repair, Panhard Rod
,
See FRONT SUSPENSION, Repair, Radius
Arm
,See FRONT SUSPENSION, Repair,
Anti-Roll Bar
,See FRONT SUSPENSION,
Repair, Front Shock Absorber
.
6.Fit new radius arm bushes using NTC 6781. Fit
new nuts, bolts and washers.
7.If problem persists fit damper kit STC 288 - 90,
STC 290 - 110/130 (2 off front) and STC 289 -
90, STC 291 - 110 levelled, STC 292 - 110
unlevelled, STC 293 - 130 (2 off rear). Road test
vehicle.
8.Check the power steering box adjustments and
operation
See Overhaul, Power Steering Box.
9.Check the hub bearing end floats and determine
the condition of the hub bearings as applicable
See FRONT AXLE AND FINAL DRIVE, Repair,
Front Hub Assembly
.
10.Check the resistance and condition of the
swivels
See FRONT AXLE AND FINAL DRIVE,
Description and operation, Description
.
If problem is not diagnosed: Repeat checks
starting at 1.
11.Carry out a full steering geometry check
See
GENERAL SPECIFICATION DATA,
Information, Steering
.

70BRAKES
2
DESCRIPTION AND OPERATION REV: 05/99 OPERATION
Master cylinder
A tandem master cylinder, which is assisted by a light
weight, short, compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank.
When the footbrake is applied, the primary plunger
assembly moves up the cylinder bore and the
pressure created acts in conjunction with the primary
spring to overcome the secondary springs, thus
moving the secondary plunger assembly up the bore.
At the same time initial movement of both plungers
takes the recuperating seals past the cut-off holes in
the cylinder chambers 'A' and 'C',see J6321, and
applies pressure to the fliud in those chambers, which
is directed to the respective circuits.
The fluid in chambers 'B' and 'D'is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers 'A' and
'C'and the recuperation seals.
The recuperation seals momentarily collapse allowing
fluid in chambers 'B' and 'D'to flow through the holes
in the plungers, over the collapsed seals and into
chambers 'A' and 'C'respectively. The movement of
fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers 'A' and 'C'to move through the cut off holes
into the fluid reservoir.The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied. Power
is obtained from a vacuum pump located on the RH
side of the engine cylinder block. The vacuum is
applied to both sides of a flexing diaphragm, and by
admitting atmosheric pressure to the rear diaphragm,
assistance is obtained. The servo unit is mounted
between the brake pedal and master cylinder and is
linked to these by push rods. Should a vacuum failure
occur, the two push rods will act as a single rod
allowing the brakes to function in the normal way,
although more effort will be required to operate the
brake pedal.
Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate as a bulb
check when the ignition is switched on and
extinguishes when the engine is running and the
handbrake is released. A hydraulic failure in the
system will result in fluid loss, causing the warning
light to illuminate.
On 90 models a pressure reducing valve (PRV), fitted
to the RH bulkhead in the engine compartment,
maintains the braking balance, see J6322. Pressure
to the rear calipers is regulated by the PRV, this valve
is of the failure by-pass type, allowing full system
pressure to the rear brake calipers in the event of a
front (secondary) circuit failure.
NOTE: In some countries, a pressure
reducing valve may be fitted to 110 models
to conform to legal requirements.

74WHEELS AND TYRES
6
REPAIRREV: 05/99 WHEELS
Remove
WARNING: The parking brake acts on
transmission, not rear wheels, and may
not hold vehicle when jacking unless
following procedure is used. If one front wheel
and one rear wheel is raised no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select a gear in main
gearbox and engage low gear in transfer box.
1.Loosen 5 wheel nuts.
2.Using a suitable trolley jack, raise vehicle and
place on axle stands
See INTRODUCTION,
Information, Jacking
.
3.Remove wheel nuts and carefully withdraw
wheel over studs.
Refit
4.Ensure that retaining studs and nuts are clean.
5.Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6.Refit wheel taking care not to damage stud
threads. (Do not apply oil).
7.Fit wheel nuts and turn by hand for at least three
full threads before using any form of wheel
wrench.
8.Tighten nuts as much as possible using a
suitable wrench.
9.Lower vehicle and finally tighten nuts to correct
torque sequence shown.
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)

ELECTRICAL
1
DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of electrical
connections at all times. Any incorrect connections
made when reconnecting cables may cause
irreparable damage to semi-conductor devices used in
generator and regulator. Incorrect polarity would also
seriously damage any transistorized equipment such
as a radio.
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect battery negative lead first. If
positive lead is disconnected with negative lead in
place, accidental contact of wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery positive lead should be
connected first.
GENERATOR
The generator is a three phase, field sensed unit. The
rotor and stator windings produce three phase
alternating current, AC, which is rectified to direct
current, DC. The electronic voltage regulator unit
controls generator output voltage by high frequency
switching of the rotor field circuit. Use only correct
replacement drive belt. Occasionally check that
engine and generator pulleys are accurately aligned.
It is essential that good electrical connections are
maintained at all times. Of particular importance are
those in the charging circuit (including those at
battery) which should be occasionally inspected to
see that they are clean and tight. In this way any
significant increase in circuit resistance can be
prevented.Do not disconnect battery cables while engine is
running or damage to semi-conductor devices may
occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while engine is running.
The electronic voltage regulator employs micro-circuit
techniques resulting in improved performance under
difficult service conditions. The whole assembly is
encapsulated in silicone rubber and housed in an
aluminium heat sink, ensuring complete protection
against adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give required regulating voltage range of 14.2±0.2
volts, and no adjustment is necessary. The only
maintenance needed is occasional check on terminal
connections and wiping with a clean dry cloth.
The generator system provides for direct connection
of a charge (ignition) indicator warning lamp, and
eliminates the need for a field switching relay or
warning light control unit. In the event of bulb failure,
an 'exciter' voltage is supplied through a resistor,
wired in parallel to the bulbs, ensuring that generator
output is maintained. The lamp should be checked
regularly.
When using rapid charge equipment to re-charge
battery, the battery must be disconnected from the
vehicle.

ELECTRICAL
3
DESCRIPTION AND OPERATION Door and bonnet switches
Perimetric protection for the vehicle is provided by
ECU inputs connected to the starter switch, bonnet
switch and door switches.
Ultrasonic sensor
The ultrasonic sensor operates by emitting an air
pressure carrier wave which is subsequently received
by the sensor as it bounces back from objects inside
the vehicle. Once armed, the alarm will sound if wave
is disturbed by a door opening, or if movement is
detected inside the vehicle.
When the volumetric sensor is activated it monitors
movement within the vehicle for 15 seconds before
detecting and responding to intrusions. If the sensor
detects movement it delays arming until a quiet period
has lapsed; if continuous movement is detected, the
alarm will not arm volumetrically.
NOTE: Interior protection will not operate
until 15 seconds after alarm is set.
The ultrasonic sensor is positioned in a different
location, according to vehicle type, as follows:
·90/110 Station Wagon - RH cantrail trim
·90/110 Pick-up - On headlining, between interior
lamp and rear view mirror
·130 Crewcab - On headlining above RH door
Alarm sounder
Two types of alarm sounder can be fitted, one with a
battery back-up facility and or without battery back-up,
both providing an audible warning whenever the alarm
is triggered. The vehicle horn will also operate if the
alarm sounds.
The alarm sounder is fitted to LH inner front wing in
the engine compartment.
NOTE: Disconnecting the battery on
vehicles fitted with the battery backed-up
facility will result in the alarm sounding, if
correct procedure has not been followed.Engine immobilisation warning light
The engine immobilisation warning light is located on
the instrument panel, and provides a visual indication
that the engine is immobilised.
Anti-theft alarm indicator light
The anti-theft alarm indicator light is located on the
instrument panel, between the fuel and coolant
temperature indicators, and provides a visual
indication of the alarm/ immobiliser status.

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.

86ELECTRICAL
6
DESCRIPTION AND OPERATION REV: 05/99 ENGINE IMMOBILISATION
Engine immobilisation is an important aspect of the
vehicle's security system, and occurs automatically
whenever the alarm system is armed.
The system also includes a feature known as 'passive
immobilisation', which is designed to safeguard the
vehicle from theft should the driver forget to arm the
alarm.
Passive immobilisation occurs automatically as
follows:
·Thirty seconds after the starter switch has been
turned off and the driver's door opened.
·Five minutes after the starter switch is turned off or
the alarm system is disarmed.
If the engine has immobilised passively,
re-mobilisation will occur when the starter switch is
turned to position 'II', provided the handset is on the
same ring as key and in close proximity to the switch.
ALWAYS keep the handset on the same ring as the
key.
NEVER attach both handsets to the same key ring.
Any attempt to start the engine while it is immobilised
will cause the engine immobilisation warning light to
flash.
Engine immobilisation override
If the handset is lost or fails to operate, the engine
immobilisation can be overridden by using the starter
key to enter the four digit emergency access code.
The procedure for entering the code is described after
the following note:
NOTE: If the handset is lost or inoperative,
it is impossible to disarm the alarm. As
soon as the door is opened, the alarm will
sound (continuously for up to three 30 second
periods), and continue while the code is being
entered.
1.With the driver's door closed, insert the key into
the starter switch.
2.Turn the switch to position 'II' the required
number of times to enter first digit of code (if first
digit is 4, turn key to position 'II' and then back to
'0' four times.
3.Open the driver's door (to enter first digit) and
then close the door again.
4.Turn the starter switch to position 'II' and back to
'0' the required number of times to enter
SECOND digit of code.
5.Open the driver's door (to enter second digit)
and then close the door again.
6.Turn the starter switch to position 'II' and back to
'0' the required number of times to enter THIRD
digit of code.
7.Open the driver's door (to enter third digit) and
then close door again.
8.Turn the starter switch to position 'II' and back to
'0' the required number of times to enter
FOURTH digit of code.
9.Finally, open and close the driver's door. If the
code has been entered correctly, the anti-theft
indicator light will extinguish, the engine can be
started and the alarm will disarm.
If an incorrect code has been entered:
If the code is entered incorrectly, the anti-theft
indicator light will continue to illuminate and the
engine will fail to start. Before entering the code again,
turn the starter switch to position 'II', hold in this
position for 5 seconds and then switch off.
After three failed attempts, the security system
invokes a delay period of thirty minutes during which
the system will not accept any further codes.