Land Rover Defender Workshop Rover Manual
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84WIPERS ANDWASHERS 6 REPAIR WINDSCREEN WIPERWHEEL BOXES-NON AIR CONDITIONED VEHICLES Service repairno-84.15.25 Remove 1. Disconnect battery. 2. Remove wiperarms SeeWindscreen wiper arms. 3. Remove wipermotorSeeWiper motor and drive rack-vehicle withairconditioning, LH drive . 4. Remove instrument housing,fasciacrashpad, and ventilator grillepanel. 5. Slacken steeringcolumnsupport rodlower fixing. 6. Remove steeringcolumnuppersupport fixing. 7. Slacken nutstorelease backplates fromLHand RH wheel boxes. 8. Remove driveracktubes. 9. Slacken grubscrews andremove wiperarm adaptors. 10. Remove LHand RHwheelbox spindlenuts. 11. Remove wheelboxassemblies fromvehicle.
WIPERSANDWASHERS 7 REPAIR Refit NOTE: During reassembly allfixings related towiper motor andwheelboxes are finger tightened only,untilallcomponents are correctly aligned. 12. Fitwheelboxes tobulkhead andsecure with retaining nutsandwashers. 13. Fitdrive racktubes towheelboxes. 14. Apply grease todrive rackandwheelboxes. 15. Align wiper motor andmounting pad,secure with retaining strapandtighten drivetubenut. 16. Fully tighten wheelbox backplate nuts. 17. Fully tighten bothwheelbox spindlenuts. 18. Fitwiper armadaptors andsecure withgrub screw. 19. Before refitting panelsfitwiper blades, connect multi-plug andearth lead,reconnect batteryand check wiperoperation. 20. Ifsatisfactory, securesteering columnupperand lower fixings andtighten tocorrect torque. 21. Fitventilator grillepanel, fasciacrashpad, instrument housingandallother components removed togain access towiper motor and wheelboxes.
84WIPERS ANDWASHERS 8 REPAIR WINDSCREEN WIPERWHEELBOXES -AIR CONDITIONED VEHICLES Service repairno-84.15.25/20 Remove 1. Disconnect battery. 2. Remove wipermotor anddrive rack SeeWiper motor anddrive rack-air conditioned vehicles. 3. Remove centreandLHfascia topcrash rail support bracketfixings. 4. Remove bothdemister ventsfromducts. 5. Remove RHdemister venthose fromduct. 6. Remove RHvent demister ventfixing andpivot vent andhose aside. 7. Remove demister venttopduct. 8. Release steeringcolumnupperandlower support rods. 9. Slacken LHand RHwheelbox nutsandremove drive tubes fromwheelboxes. 10. Remove wiperarmsplined adaptor. 11. Remove spacer,wherefitted,earlyvehicles only. 12. Remove nutssecuring leftand RHwheel boxes and withdraw wheelboxes frombulkhead. NOTE: During assembly allfixings related to wiper motor andwheelboxes arefinger tightened onlyuntil allcomponents are correctly aligned.
WIPERSANDWASHERS 9 REPAIR 13. Fitwheelboxes tobulkhead. 14. Fitdrive tubes towheelboxes. 15. Feed driverackthrough tubesuntilfullyseated in both wheelboxes. 16. Secure drivetubenuttowiper motor. 17. Fitwiper motor strapandearth lead. 18. When allcomponents arecorrectly aligned,fully tighten wheelboxes nutstosecure drivetubes. Tighten wheelbox tobulkhead nuts. 19. Fully tighten drivetubenuttowiper motor and motor strapscrews. 20. Connect multiplug towiper motor andearth lead to strap tag. 21. Fitspacer, whereused,earlyvehicles only. 22. Fitwiper armadaptors. 23. Reconnect batteryandcheck operation ofwiper motor anddrive assembly andwheelboxes. 24. Disconnect battery. 25. Fitsteering columnupperandlower supports. Tighten fixingstocorrect torque. 26. Fitdemister venttopduct. 27. Secure RHdemister ventandhose. 28. FitLH and RHdemister ventstoducts. 29. Fitcentre andLHfascia topcrash railsupport brackets. 30. Fitallother components removedtogain access to wiper motor andwheelboxes. 31. Reconnect battery,checkwipermotor operation again andadjust wiperarms, ifnecessary. REAR WIPER MOTOR Service repairno-84.35.12 Remove 1. With assistance, unscrew3retaining nutsand remove sparewheel fromreardoor mounting studs. 2. Lift wiper armendcaptogain access tosecuring nut. 3. Remove nutand withdraw wiperarmfrom drive spindle. 4. Remove retaining nut,plain washer andrubber washer securing wipermotor drivespindle to door. 5. Remove 2screws andremove coverfromwiper motor mounting bracket. 6. Disconnect wipermotor harness multi-plug. 7. Remove bolt,withrubber washer, anddetach wiper motor, complete withmounting bracket, from reardoor.
84WIPERS ANDWASHERS 10 REPAIR Refit 8. Locate wipermotor drivespindle through aperture inrear door. 9. Position wipermotor mounting bracketand secure torear door. Tighten boltto 23Nm (17 lbf/ft). 10. Reconnect harnessmulti-plug. 11. Secure drivespindle todoor. 12. Fitwiper motor cover. 13. Fitrear wiper arm. 14. Fitspare wheel. Tighten retaining nutsto 130Nm (96 lbf/ft).
WIPERSANDWASHERS 1 OVERHAUL WIPER MOTOR Service repairno-84.15.18. Dismantle 1. Remove wipermotor fromvehicle SeeRepair, Wiper motor anddrive rack. 2.Remove wipermotor gearbox cover. 3. Remove circlipandplain washer securing connecting rod. 4. Withdraw connecting rod. 5. Withdraw flatwasher. 6. Remove circlipandwasher securing shaftand gear. 7. Clean anyburrs fromgear shaft andwithdraw gear. 8. Withdraw dishedwasher. 9. Add alignment markstoyoke andgearbox for reassembly. 10. Remove yokesecuring bolts. 11. Withdraw yokeandarmature. 12. Remove brushgearassembly. 13. Remove limitswitch. Inspection andtest 14. Check brushes forexcessive wear,ifthey are worn to4,8 mm inlength, fitanew brush gear assembly. 15. Using apush typegauge, checkthatbrush spring pressure is140 to200 gwhen bottom of brush islevel withbottom ofslot inbrush box.Fit a new brush gearassembly ifsprings arenot satisfactory. 16. Test armature forinsulation andopen- or short-circuits. Usea110 V15 W test lamp. Fita new armature iffaulty. 17. Examine gearwheel fordamage orexcessive wear. Key towiper motor components 1. Flexible drive 2. Gearbox cover 3. Connecting-rod retainingwasherandcirclip 4. Connecting-rod 5. Flat washer 6. Gear shaftretaining washerandcirclip 7. Drive gear 8. Dished washer 9. Alignment marks-yoke tobody 10. Yoke securing bolts 11. Armature andyoke 12. Brush gearassembly 13. Limit switch
84WIPERS ANDWASHERS 2 OVERHAUL Assemble Use Ragosine ListateGrease tolubricate gearwheel teeth, armature shaftworm gear,connecting rodand pin, cable rackandwheelbox gearwheels. Use Shell Turbo 41oilsparingly tolubricate bearing bushes, armature shaftbearing journals, gearwheel shaft andwheelbox spindles.Thoroughly soakfelt washer inyoke bearing withoil. 18. Fitlimit switch. 19. Fitbrush gearassembly. 20.Fitarmature andyoke togearbox using alignment marks,secure withyoke retaining bolts tightening to 23Nm (17lbf/ft).Ifa replacement armatureisbeing fittedslacken thrust screw toprovide end-float forfitting yoke. 21. Fitdished washer beneath gearwheel with concave sidetowards gearwheel. 22. Fitgear wheel togearbox. 23. Secure gearwheel shaftwithplain washer and circlip. 24. Fitlarger flatwasher overcrankpin. 25. Fitconnecting rodand secure withsmaller plain washer andcirclip. 26. Fitgearbox coverandsecure withretaining screws. 27. Connect electrical leadsbetween wipermotor and limit switch. 28. Toadjust armature shaftend-float, holdyoke vertically withadjuster screwuppermost. Carefully screwinadjuster untilresistance isfelt, then back-off onequarter turn.
ELECTRICAL1 DESCRIPTION ANDOPERATION ELECTRICAL EQUIPMENT Description The electrical systemisNegative ground,anditis most important toensure correctpolarity ofelectrical connections atall times. Anyincorrect connections made whenreconnecting cablesmaycause irreparable damagetosemi-conductor devicesusedin generator andregulator. Incorrectpolaritywouldalso seriously damageanytransistorized equipmentsuch as aradio. WARNING: Duringbattery removal or before carrying outany repairs or maintenance toelectrical components always disconnect batterynegative leadfirst. If positive leadisdisconnected withnegative leadin place, accidental contactofwrench toany grounded metalpartcould cause asevere spark, possibly resulting inpersonal injury.Upon installation ofbattery positive leadshould be connected first. GENERATOR The generator isathree phase, fieldsensed unit.The rotor andstator windings producethreephase alternating current,AC,which isrectified todirect current, DC.The electronic voltageregulator unit controls generator outputvoltage byhigh frequency switching ofthe rotor fieldcircuit. Useonly correct replacement drivebelt.Occasionally checkthat engine andgenerator pulleysareaccurately aligned. It is essential thatgood electrical connections are maintained atall times. Ofparticular importance are those inthe charging circuit(including thoseat battery) whichshould beoccasionally inspectedto see that they areclean andtight. Inthis way any significant increaseincircuit resistance canbe prevented. Do not disconnect batterycableswhileengine is running ordamage tosemi-conductor devicesmay occur. Itis also inadvisable tobreak ormake any connections inthe generator chargingandcontrol circuits whileengine isrunning. The electronic voltageregulator employsmicro-circuit techniques resultinginimproved performance under difficult service conditions. Thewhole assembly is encapsulated insilicone rubberandhoused inan aluminium heatsink, ensuring complete protection against adverse effectsoftemperature, dust,and moisture etc. The regulating voltageisset during manufacture to give required regulating voltagerangeof14.2 ±0.2 volts, andnoadjustment isnecessary. Theonly maintenance neededisoccasional checkonterminal connections andwiping withaclean drycloth. The generator systemprovides fordirect connection of acharge (ignition) indicatorwarninglamp,and eliminates theneed forafield switching relayor warning lightcontrol unit.Inthe event ofbulb failure, an exciter voltageissupplied througharesistor, wired inparallel tothe bulbs, ensuring thatgenerator output ismaintained. Thelamp should bechecked regularly.When usingrapidcharge equipment tore-charge battery, thebattery mustbedisconnected fromthe vehicle.
86ELECTRICAL 2 DESCRIPTION ANDOPERATION VEHICLE IMMOBILISATION ANDALARM SYSTEM A sophisticated engineimmobilisation andanti-theft alarm system isoffered onthe Land Rover Defender 300 Tdivehicle range,whichincorporates the following features: Perimeter protection This partofthe alarm system protects sidedoors, bonnet andrear door against unauthorised entry- alarm sounding ifany one ofthese apertures is opened withoutalarmfirstbeing disarmed. Interior protection Also known asvolumetric protection, thispart ofthe system protects spaceinsidethevehicle. Once armed, thealarm willsound ifa door isopened, orif movement isdetected insidethevehicle. Engine immobilisation The engine isimmobilised electronically wheneverthe alarm system isarmed. Evenifthe alarm hasnot been armed, engineimmobilisation willoccur automatically thirtyseconds afterthedrivers dooris opened, orfive minutes afterthestarter switchis turned toposition 0. ALARM SYSTEM COMPONENTS Electronic controlunit(ECU) The ECU isthe alarm system brainandcontrols all vehicle immobilisation andalarm functions. It responds tothe inputs received, bysupplying suitable outputs toindicate statusofthe alarm system or activating relevantwarningdevices. unitislocated under fascia behind instrument binnacle. Handset andkey The handset isthe primary sourceofcontrol forthe alarm system i.e.itarms anddisarms thealarm components. Thekeycan beused tooverride engine immoblisation ifthe handset islost orfails tooperate, see Engine immobilisation override. The handset batteryshouldlastforapproximately three years dependent uponuse.Thefollowing symptoms willbenoticed whenthebattery requires replacement: 1. The handset willonly work every otheroperation while disarming. 2. The direction indicatorlampswillnot flash when the alarm isdisarmed. For battery replacement procedure,seeHandset Battery. Passive coil The passive coilisfitted onthe starter switchand activates areceiving coilinthe handset, causingitto automatically transmitaremobilisation signaltothe ECU.AerialThe aerial isintegral withinthealarm system harness and supplies theECU withthesignal received from handset.Immobilisation spider The immobilisation spiderprovides aninterface between ECUandimmobilised areasofthe vehicle. This isinstalled inasealed (safe)boxinside the vehicle batterybox. Digital dieselshut-off valve-97 M Y When fitted,thedigital diesel shut-off valve immobilises thefuel injection pumpbypreventing power reaching thefuel shut-off solenoid, See Immobilisation andalarm system circuitdiagram - with DDS .
ELECTRICAL3 DESCRIPTION ANDOPERATION Door andbonnet switches Perimetric protectionforthe vehicle isprovided by ECU inputs connected tothe starter switch, bonnet switch anddoor switches. Ultrasonic sensor The ultrasonic sensoroperates byemitting anair pressure carrierwavewhich issubsequently received by the sensor asitbounces backfromobjects inside the vehicle. Oncearmed, thealarm willsound ifwave is disturbed byadoor opening, orifmovement is detected insidethevehicle. When thevolumetric sensorisactivated itmonitors movement withinthevehicle for15seconds before detecting andresponding tointrusions. Ifthe sensor detects movement itdelays arming untilaquiet period has lapsed; ifcontinuous movementisdetected, the alarm willnot arm volumetrically. NOTE: Interior protection willnotoperate until 15seconds afteralarm isset. The ultrasonic sensorispositioned inadifferent location, according tovehicle type,asfollows: 90/110 Station Wagon -R H cantrail trim 90/110Pick-up -O n headlining, betweeninterior lamp andrear view mirror 130Crewcab -O n headlining aboveRHdoor Alarm sounder Two types ofalarm sounder canbefitted, onewith a battery back-up facilityandorwithout batteryback-up, both providing anaudible warning whenever thealarm is triggered. Thevehicle hornwillalso operate ifthe alarm sounds. The alarm sounder isfitted toLH inner frontwing in the engine compartment. NOTE: Disconnecting thebattery on vehicles fittedwiththebattery backed-up facility willresult inthe alarm sounding, if correct procedure hasnotbeen followed. Engine immobilisation warninglight The engine immobilisation warninglightislocated on the instrument panel,andprovides avisual indication that theengine isimmobilised. Anti-theft alarmindicator light The anti-theft alarmindicator lightislocated onthe instrument panel,between thefuel and coolant temperature indicators,andprovides avisual indication ofthe alarm/ immobiliser status.