Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							WIPERS AND WASHERS
5
REPAIR Refit
8.Locate wiper motor drive spindle through
aperture in rear door.
9.Position wiper motor mounting bracket and
secure to rear door. Tighten bolt to
23 Nm, 17
lbf/ft.
10.Reconnect harness multi-plug.
11.Secure drive spindle to door.
12.Fit wiper motor cover.
13.Align wiper arm to bottom of heater element and
push arm onto spindle, tighten nut and fit end
cap.
14.Fit spare wheel. Tighten retaining nuts to
130Nm, 95 lbf/ft. 
						

							WIPERS AND WASHERS
1
OVERHAUL WIPER MOTOR
Service repair no - 84.15.18.
Dismantle
1.Remove wiper motor from vehicle.
See Repair,
Wiper motor and drive rack
2.Remove wiper motor gearbox cover.
3.Remove circlip and plain washer securing
connecting rod.
4.Withdraw connecting rod.
5.Withdraw flat washer.
6.Remove circlip and washer securing shaft and
gear.
7.Clean any burrs from gear shaft and withdraw
gear.
8.Withdraw dished washer.
9.Add alignment marks to yoke and gearbox for
reassembly.
10.Remove yoke securing bolts.11.Withdraw yoke and armature.
12.Remove brush gear assembly.
13.Remove limit switch.
Inspection and test
14.Check brushes for excessive wear, if they are
worn to 4,8 mm in, 0.21 in length, fit a new brush
gear assembly.
15.Using a push type gauge, check that brush
spring pressure is 140 to 200 g, 5 to 7 oz when
bottom of brush is level with bottom of slot in
brush box. Fit a new brush gear assembly if
springs are not satisfactory.
16.Test armature for insulation and open- or
short-circuits. Use a 110 V 15 W test lamp. Fit a
new armature if faulty.
17.Examine gear wheel for damage or excessive
wear.
Key to wiper motor components
1.Flexible drive
2.Gearbox cover
3.Connecting-rod retaining washer and circlip
4.Connecting-rod
5.Flat washer
6.Gear shaft retaining washer and circlip
7.Drive gear8.Dished washer
9.Alignment marks - yoke to body
10.Yoke securing bolts
11.Armature and yoke
12.Brush gear assembly
13.Limit switch 
						

							84WIPERS AND WASHERS
2
OVERHAUL Assemble
Use Ragosine Listate Grease to lubricate gear wheel
teeth, armature shaft worm gear, connecting rod and
pin, cable rack and wheelbox gear wheels.
Use Shell Turbo 41 oil sparingly to lubricate bearing
bushes, armature shaft bearing journals, gear wheel
shaft and wheelbox spindles. Thoroughly soak felt
washer in yoke bearing with oil.
18.Fit limit switch.
19.Fit brush gear assembly.
20.Fit armature and yoke to gearbox using
alignment marks, secure with yoke retaining
bolts tightening to
23 Nm, 17 lbf/ft.If a
replacement armature is being fitted slacken
thrust screw to provide end-float for fitting yoke.21.Fit dished washer beneath gear wheel with
concave side towards gear wheel.
22.Fit gear wheel to gearbox.
23.Secure gear wheel shaft with plain washer and
circlip.
24.Fit larger flat washer over crankpin.
25.Fit connecting rod and secure with smaller plain
washer and circlip.
26.Fit gearbox cover and secure with retaining
screws.
27.Connect electrical leads between wiper motor
and limit switch.
28.To adjust armature shaft end-float, hold yoke
vertically with adjuster screw uppermost.
Carefully screw in adjuster until resistance is felt,
then back-off one quarter turn. 
						

							WIPERS AND WASHERS
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Nm lbf ft
Wiper motor to yoke bolts 23................................................ 17
Rear wiper motor mounting bracket bolts 23........................ 17
Spare wheel 130..................................................................... 95 
						

							ELECTRICAL
1
DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of the
electrical connections at all times. Any incorrect
connections made when reconnecting cables may
cause irreparable damage to the semi-conductor
devices used in the 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 the battery negative - lead
first. If the positive + lead is disconnected with
the negative - lead in place, accidental contact of
the wrench to any grounded metal part could
cause a severe spark, possibly resulting in
personal injury. Upon installation of the battery
the positive + lead must be connected first.
GENERATOR
The generator is a 3 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 the generator output voltage by high
frequency switching of the rotor field circuit. Use only
the correct auxiliary drivebelt. Occasionally check that
the 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 the
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 the engine is
running or damage to the semi-conductor devices
may occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while the 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 the adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give the required regulating voltage range of 14.2±
0.2 volts, and no adjustment is necessary. The only
maintenance needed is the 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 light, and
eliminates the need for a field switching relay or
warning light control unit. The lamp should be
checked regularly. In the event of bulb failure, an
exciter voltage is supplied through a resistor, wired in
parallel to the bulb, ensuring that generator output is
maintained.
When using rapid charge equipment to re-charge the
battery, the battery MUST be disconnected from the
vehicle. 
						

							ELECTRICAL
1
REPAIR ELECTRICAL PRECAUTIONS
The following [fender]guidelines are intended to
ensure the safety of the operator whilst preventing
damage to electrical and electronic components fitted
to the vehicle.
Polarity
Never reverse connect the vehicle battery and always
observe the correct polarity when connecting test
equipment.
High voltage circuits
WARNING: Before commencing work on
an ignition system, all high tension
terminals, adaptors and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimize the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Whenever disconnecting live high tension circuits
always use insulated pliers and never allow the open
end of a high tension lead to come into contact with
other components particularly electronic control units.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, since, high
voltage spikes can occur on these terminals.
Connectors and harness
Always ensure that these items are dry and oil free
before disconnecting and connecting test equipment.
Never force connectors apart either by using tools or
by pulling on the wiring harness. Always ensure
locking tabs are disengaged before removal and note
orientation to enable correct reconnection. Ensure that
any protective covers and substances are replaced if
disturbed. Having confirmed a component to be faulty
switch-off the ignition and disconnect the battery.
Remove the component and support the disconnected
harness. When replacing the component keep oily
hands away from electrical connection areas and
push connectors home until any locking tabs fully
engage.Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately 15 minutes
afterwards, batteries emit hydrogen gas which is
flammable. Always ensure any battery charging area
is well ventilated and that every precaution is taken to
avoid naked flames and sparks.
GENERAL PRECAUTIONS
Switch-off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting live connections can
damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only.
Prior to commencing a test, and periodically during a
test, touch a good earth, for instance, a cigar lighter
socket, to discharge body static as some electronic
components are vulnerable to static electricity. 
						

							86ELECTRICAL
2
REPAIR BATTERY
Service repair no - 86.15.01
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 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.Refit
6.Clean off corrosion and neutralize. Coat battery
clamps and terminals with petroleum jelly.
7.Position battery and secure with clamp. Ensure
J bolts are hooked correctly under retaining
brackets on base of battery box.
8.Reconnect battery leads, positive + lead first.
9.Fit battery access cover and secure with clip.
10.Fit seat cushion. 
						

							ELECTRICAL
3
REPAIR HEADLAMP
Service repair no - 86.40.02
Remove
1.Remove screws retaining side and direction
indicator lamps.
2.Withdraw lamp units and disconnect plugs.
Remove 2 screws and release indicator lamp
boss from headlamp finisher.
3.Remove 2 screws and withdraw headlamp
finisher.
4.Remove 2 headlamp retaining screws.
5.Rotate headlamp clockwise, disengage from
body, and lift out headlamp.
6.Disconnect multi-plug to release headlamp.
7.Remove rubber cover.
8.Remove headlamp assembly.Refit
9.Fit rubber cover and reconnect multi-plug.
10.Locate headlamp in body and rotate
anti-clockwise to engage.
11.Fit headlamp retaining screws.
12.Fit headlamp finisher, side and direction
indicator lamps.
13.Check main beam alignment.
See Headlamp
beam alignment 
						

							86ELECTRICAL
4
REPAIR HEADLAMP BEAM ALIGNMENT
Service repair no - 86.40.17
Check
Check main beam alignment using beam setting
equipment. Should this not be available the beam can
be temporarily checked and adjusted as follows:-
1.Position vehicle, unladen, on level ground with
tyres correctly inflated, approximately 4 meters
from a wall or screen, marked as illustrated
below.
2.The beam centres A are measured horizontally
on the vehicle and headlamp centre dimension
B vertically from the ground.
3.Switch on main beam and adjust setting, as
necessary, with trimmer screws.SIDE, TAIL AND INDICATOR LAMPS
Service repair no - 86.40.34 Parking lamp
Service repair no - 86.40.42 Indicator lamp
Service repair no - 86.40.45 Tail lamp, indicator
lamp
Service repair no - 86.40.91 Reverse lamp
Remove
1.Release 2 screws and withdraw lens.
2.Twist counter-clockwise and withdraw bulb
holder.
3.Remove bulb, bayonet fixing.
4.Disconnect bulb holder from multiplug.
5.If necessary, remove 2 screws and withdraw
lamp boss.
Refit
6.Fit lamp boss, if applicable.
7.Connect bulb holder to multiplug.
8.Fit bulb of same wattage, if renewed.
9.Fit lens. 
						

							ELECTRICAL
5
REPAIR REAR NUMBER PLATE LAMP - BULB RENEWAL
Service repair no - 86.40.85
Remove
1.Remove single screw securing lamp cover and
lens to bulb holder.
2.Remove bulb/s from holder.
Refit
3.Fit new bulb/s.
4.Fit lamp lens and cover.REAR NUMBER PLATE LAMP
Service repair no - 86.40.86
Remove
1.Remove single screw and remove lamp cover
and lens.
2.Remove rear speaker.
See CHASSIS AND
BODY, Repair, Radio speaker - rear
3.Through speaker aperture, disconnect lamps
leads from harness.
4.Remove 2 bolts, nuts and washers securing
lamp to vehicle body.
5.Remove bulb holder, complete with rubber seal
and mounting plinth.
Refit
6.Feed lamp unit leads through vehicle body and
secure bulb holder, seal and plinth.
7.Fit lamp leads to harness connectors.
8.Fit radio speaker.
See CHASSIS AND BODY,
Repair, Radio speaker - rear
9.Fit lens and lamp cover.