Land Rover Defender Workshop Rover Manual

							ELECTRICAL1
REPAIR
ELECTRICAL
PRECAUTIONS
The following guidelines areintended toensure the
safety ofthe operator whilstpreventing damageto
electrical andelectronic components fittedtothe
vehicle. PolarityNever reverse connect thevehicle batteryandalways
observe thecorrect polarity whenconnecting test
equipment.High voltage circuits
WARNING: Beforecommencing workon
an ignition system, allhigh tension
terminals, adaptorsanddiagnostic
equipment fortesting should beinspected to
ensure thatthey areadequately insulatedand
shielded toprevent accidental personalcontacts
and minimize therisk ofshock. Wearers of
surgically implanted pacemaker devicesshould
not beinclose proximity toignition circuitsor
diagnostic equipment.
Whenever disconnecting livehigh tension circuits
always useinsulated pliersandnever allowtheopen
end ofahigh tension leadtocome intocontact with
other components particularlyelectroniccontrolunits.
Exercise cautionwhenmeasuring thevoltage onthe
coil terminals whiletheengine isrunning, since,high
voltage spikescanoccur onthese terminals.
Connectors andharness
Always ensurethatthese itemsaredryand oilfree
before disconnecting andconnecting testequipment.
Never forceconnectors aparteither byusing toolsor
by pulling onthe wiring harness. Alwaysensure
locking tabsaredisengaged beforeremoval andnote
orientation toenable correct reconnection. Ensurethat
any protective coversandsubstances arereplaced if
disturbed. Havingconfirmed acomponent tobe faulty
switch-off theignition anddisconnect thebattery.
Remove thecomponent andsupport thedisconnected
harness. Whenreplacing thecomponent keepoily
hands awayfromelectrical connection areasand
push connectors homeuntilanylocking tabsfully
engage. Battery
disconnecting
Before disconnecting thebattery, switchoffall
electrical equipment.
Battery charging
Recharge thebattery outofthe vehicle andkeep the
top well ventilated. Whilebeingcharged or
discharged, andforapproximately 15minutes
afterwards, batteriesemithydrogen gaswhich is
flammable. Alwaysensureanybattery charging area
is well ventilated andthatevery precaution istaken to
avoid naked flames andsparks.
GENERAL PRECAUTIONS
Switch-off ignitionpriortomaking anyconnection or
disconnection inthe system aselectrical surge
caused bydisconnecting liveconnections can
damage electronic components.
Ensure handsandwork surfaces areclean andfree of
grease, swarf,etc.asgrease collects dirtwhich can
cause tracking orhigh-resistance contacts.
When handling printedcircuitboards, treatthem as
you would adisc -hold bythe edges only.
Prior tocommencing atest, andperiodically duringa
test, touch agood earth, forinstance, acigar lighter
socket, todischarge bodystatic assome electronic
components arevulnerable tostatic electricity.  
						

							86ELECTRICAL
2 REPAIR
BATTERY Service
repairno-86.15.01
NOTE: Ifthe vehicle isfitted withabattery
backed-up alarmsounder, disconnecting
the vehicle batterywillcause thealarm to
sound unless thefollowing procedure isfollowed:
1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3. Slacken batterynegative leadclamp bolt.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batteryWITHIN 15SECONDS.
If alarm isaccidentally activated,ensuresounder is
connected andsilence byturning thestarter switchto
position II. Remove
WARNING:
Duringbattery removal or
before carrying outany repairs or
maintenance toelectrical components
always disconnect negativeleadfirst. Ifpositive
lead isdisconnected withnegative leadinplace,
accidental contactofawrench toany grounded
metal partcould cause asevere spark,possibly
resulting inpersonal injury.Uponinstallation of
battery alwaysconnect positiveleadfirst.
1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3.Disconnect bothbattery leads,negative first.
4. Slacken securing nutsandmove battery clamp,
with Jbolts aside.
5. Remove battery.
NOTE:Coatbattery clamps andterminals
with petroleum jellybefore refitting.
Refit 6. Position batteryandsecure withclamp. Ensure
J bolts arehooked correctly underretaining
brackets onbase ofbattery box.
7. Reconnect batteryleads,positive leadfirst.
8. Fitbattery access cover.
9. Fitseat cushion.  
						

							ELECTRICAL3
REPAIR
ELECTRONIC
CONTROLUNIT(ECU)
Service repairno-86.55.85
Remove 1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3. Slacken batterynegative leadclamp bolt.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batterynegative lead.
NOTE:Operation 6needs tobe carried out
within 15seconds toavoid activating
battery backed-up alarmsounder, iffitted.
7. Remove steeringwheel
SeeSTEERING,
Repair, Steering wheel.
8.Remove 4screws securing instrument panelto
fascia cowl
SeeINSTRUMENTS, Repair,
Instrument panel.
9.Pull instrument panelawayfromfascia cowland
disconnect speedometer cable,multi-plugs,
alarm LEDpluglead, heated rearscreen lead,
gearbox oiltemperature leadandimmobiliser
warning lightleads.
10. Remove instrument panel.
11. Remove 2screws securing ECUtofascia cowl
(LH drive shown). OnRH drive vehicles ECUis
positioned lowerdown, onvertical faceoffascia
panel.
12. Release ECUfromfascia cowlanddisconnect
both multi-plugs.
13. Remove ECU.
NOTE:Anew ECU must beinitialised
using TestBook.
Refit 14. Position ECUatfascia cowlandreconnect both
multi-plugs.
15. Locate ECUonmounting faceoffascia cowland
secure with2screws.
16. Position instrument paneltofascia cowland
reconnect immobiliser warninglightleads,
gearbox oiltemperature lead,heated rearscreen
lead, alarm LEDpluglead, multi-plugs and
speedometer cable.
17.Secure instrument paneltofascia cowlwith4
screws
See INSTRUMENTS, Repair,
Instrument panel.
18.Fitsteering wheelSeeSTEERING, Repair,
Steering wheel.
19.Reconnect batterynegative lead.
20. Fitbattery access cover.
21. FitLH seat cushion.   
						

							86ELECTRICAL
4 REPAIR
HANDSET
BATTERY
Service repairno-86.77.13
Remove 1. Unlock vehicle anddisarm alarmsystem.
2. Turn starter switchtoposition II.
3. Turn starter switchbacktoposition 0and
remove key.
4.Carefully prisehandset apart,starting from
keyring end,using acoin orsmall screwdriver.
5. Slide battery outfrom retaining clip.
6. Press andhold oneofthe handset buttonsforat
least fiveseconds todrain anyresidual power
from handset.
NOTE: Theengine willimmobilise five
minutes afterkeyisremoved fromstarter
switch. Refit
7. Fitnew battery intohandset retaining clipwith
positive sideuppermost. Fingermarkswill
adversely affectbattery life;ifpossible, avoid
touching flatsurfaces ofbattery andwipe clean
before fitting.
8. Reassemble twohalves ofhandset.
9. Press RH(Padlock) buttonatleast fourtimes
within range ofvehicle toresynchronise handset.
10. Check operation ofalarm system.
WARNING: Thehandset contains delicate
electronic circuitsandmust beprotected
from impact andwater damage, high
temperatures andhumidity, directsunlight and
effects ofsolvents, waxesandabrasive cleaners.
NOTE:Newhandsets mustbebe
initialised usingTestBook.  
						

							ELECTRICAL5
REPAIR
PASSIVE
COIL
Service repairno-86.77.35
Remove 1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3. Slacken batterynegative leadclamp bolt.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batterynegative lead.
NOTE:Operation 6needs tobe carried out
within 15seconds toavoid activating
battery backed-up alarmsounder, iffitted.
7. Remove steeringwheel
SeeSTEERING,
Repair, Steering wheel.
8.Remove 4screws securing instrument panelto
fascia cowl
SeeINSTRUMENTS, Repair,
Instrument panel.
9.Pull instrument panelawayfromfascia and
disconnect speedometer cable,multi-plugs,
alarm LEDpluglead, heated rearscreen lead,
gearbox oiltemperature leadandimmobiliser
warning lightleads.
10. Remove instrument panel.
11. Remove 7screws securing upperandlower
halves ofnacelle tosteering columnmounting
bracket
See STEERING, Repair,Steering
column nacelle.
12.Release multi-switch gaitersfrombothsides of
nacelle.
13. Remove nacelleupperandlower halves from
steering column;collectblanking grommet from
RH side.
14. Disconnect multi-plugandremove passive coil
from starter switch.
Refit 15. Feed passive coilplug leadintofascia cowlarea
and reconnect multi-plug.
16. Fitcoil onstarter switch.
17. Position nacelleupperandlower halves to
steering columnmounting bracketandsecure
with 7screws. Donot fully tighten screws atthis
stage
See STEERING, Repair,Steering
column nacelle.
18.Check thatpassive coilisstill fitted correctly on
starter switch.
19.Check fitof nacelle atstarter switchandsteering
column andfully tighten fixingscrews.
20. Fitmulti-switch gaiterstoboth sides ofnacelle
and check thatblanking grommet islocated.
21. Position instrument paneltofascia cowlarea
and reconnect immobiliser warninglightleads,
gearbox oiltemperature lead,heated rearscreen
lead, alarm LEDpluglead, mainharness multi-
plugs andspeedometer.
22. Secure instrument paneltofascia cowlwith4
screws
See INSTRUMENTS, Repair,
Instrument panel.
23.Fitsteering wheelSeeSTEERING, Repair,
Steering wheel.
24.Reconnect batterynegative lead.
25. Fitbattery access cover.
26. FitLH seat cushion.
27. Test immobilisation andalarm system.   
						

							86ELECTRICAL
6 REPAIR
IMMOBILISATION
SPIDER
Service repairno-86.77.03
Remove 1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3. Slacken batteryleadclamp bolts.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batteryleads.
NOTE: Operation 6needs tobe carried out
within 15seconds toavoid activating
battery backed-up alarmsounder, iffitted.
7. Remove batteryclampandJbolts.
8. Remove 4nuts securing immobilisation spider
housing boxtofixing studs onfront faceof
battery box.
9. Remove grommet securingspiderharness to
corner faceofbattery box.
10. Carefully pullharness intobattery box,liftspider
housing boxand place onfront edge ofseat
base.
11. Using asuitable sheettoprotect insideof
vehicle, grindheads off6monobolts securinglid
to spider boxhousing.
12. Detach lidfrom housing anddisconnect spider
harness plug.
13. Unscrew twonuts andremove immobilisation
spider fromlidstuds.
NOTE: Ifspider boxlidand/or sealing
gasket isdamaged duringoperation 11a
new lidwill need tobe fitted.
NOTE: Anew immobilisation spidermust
be initialised usingTestBook.
Refit 14. Fitimmobilisation spiderontolidstuds and
secure withretaining nuts.
15. Reconnect harnessplugtospider andensure it
fully clicks home.
16. Position lidand spider assembly intobox
housing sothat harness plugisfurst away from
harness entry.
17.Secure lidtospider boxhousing withmonobolts.
18. Refit harness grommet intospider box,if
disturbed onremoval procedures, andensure
harness covering isfully inserted through
grommet tomake watertightseal.
19. Push excess harnescablethrough cornerface
of battery boxand fitgrommet.
20. Fitspider housing boxtofixing studs andsecure
with fournuts.
21. FitJbolts andclamp tosecure battery,
22. Reconnect batteryleads.
23. Fitbattery access cover.
24. FitLH seat cushion.
25. Test immobilisation andalarm system.  
						

							ELECTRICAL7
REPAIR
BONNET
SWITCH
Service repairno-86.55.89
Remove
1. Disconnect bonnetswitchharness multi-plug.
2. Release harnessretaining clipfrom switch
mounting bracket.
3. Press inretaining clipsandremove switchfrom
mounting bracket.
Refit 4. Insert harness multi-plug andbonnet switchinto
mounting bracket.Pushswitch firmlydown to
secure inposition.
5. Connect harnessmulti-plug.
6. Fitharness retaining clipinmounting bracket. ULTRASONIC
SENSOR
Service repairno-86.77.32
Remove
1. Carefully priseultrasonic sensorfromcantrail
trim.
2. Disconnect harnessplugandremove sensor.
NOTE:Position ofsensor willchange
according tovehicle type.
Refit 3. Connect harnessplugtosensor.
4. Fitsensor tocantrail trim.    
						

							86ELECTRICAL
8 REPAIR
ALARM
SOUNDER
Service repairno-86.55.87
Remove 1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3. Slacken batterynegative leadclamp bolt.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batterynegative lead.
NOTE:Operation 6needs tobe carried out
within 15seconds toavoid activating
battery backed-up alarmsounder, iffitted.
NOTE: Ifan alarm sounder withoutbattery
back-up isfitted, itis not necessary to
disconnect battery.
7. Remove 2nuts securing powersteering pump
reservoir mounting brackettofront, LHinside
wing.
8. Move steering pumpreservoir asidetogain
access toalarm sounder.
9. Disconnect harnessmulti-plug fromrearofalarm
sounder.
10. Unscrew 2bolts andremove alarmsounder from
inside wing.
Top illustration -alarm sounder withbattery
back-up. Lower illustration -alarm sounder without
battery back-up.
NOTE: Anew battery backed-up alarm
sounder willnotoperate untilcharged by
vehicle generator forapproximately three
hours. Refit
11. Secure alarmsounder toinside wing,tightening
bolts to
10Nm (7lbf/ft).
12. Reconnect multi-plugtoalarm sounder.
13. Secure powersteering pumpreservoir toinside
wing, tightening nutsto
10Nm (7lbf/ft).
14. Reconnect batterynegative lead.
15. Fitbattery access cover.
16. FitLH seat cushion.  
						

							ELECTRICAL9
REPAIR
ALARM
SOUNDER RELAY
Service repairno-86.77.09
Remove 1. Remove screwandliftoff LH door check strap
cover.
2. Remove 3screws andlower wipermotor cover
from fascia bulkhead, (onRHdrive models first
remove grabhandle).
3.Slide relaymulti-plug fromretaining bracketand
remove relay.
Refit 4. Secure multi-plug tomounting bracketandfit
new relay.
5. Position wipermotor coverandsecure with3
screws.
6. On RH drive models fitgrab handle.
7. Fitdoor check strapandsecure withscrew. ANTI-THEFT
ALARMINDICATOR LIGHT
Service repairno-86.45.61
Remove 1. Remove LHfront seatcushion.
2. Release retaingclipand remove batteryaccess
cover.
3. Slacken batterynegative leadclamp bolt.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batterynegative lead.
NOTE:Operation 6needs tobe carried out
within 15seconds toavoid activating
battery backed-up alarmsounder, iffitted.
NOTE: Ifan alarm sounder withoutbattery
back-up isfitted, itis not necessary to
disconnect battery.
7. Remove steeringwheel
SeeSTEERING,
Repair, Steering wheel.
8.Remove 4screws securing instrument panelto
fascia cowl.
9. Pull instrument panelawayfromfascia and
disconnect speedometer cable,ifnecessary.
10. Disconnect alarmindicator lightplug lead.
11. Press inretaining lugsandwithdraw indicator
light from fascia panel.    
						

							86ELECTRICAL
10 REPAIR
Refit
12. Fitalarm indicator lightintofascia paneland
reconnect pluglead.
13. Reconnect speedometer cableandfitinstrument
panel tofascia cowl.
14. Fitsteering wheel
SeeSTEERING, Repair,
Steering wheel.
15.Reconnect batterynegative lead.
16. Fitbattery access cover.
17. FitLH seat cushion. ALARM
SYSTEM FUSE
Service repairno-86.77.04
Remove 1. Remove LHfront seatcushion.
2. Release retaining clipand remove battery
access cover.
3. Slacken batterynegative leadclamp bolt.
4. Turn starter switchon.
5. Turn starter switchoffand remove key.
6. Disconnect batterynegative lead.
NOTE:Operation 6needs tobe carried out
within 15seconds toavoid activating
battery backed-up alarmsounder, iffitted.
NOTE: Ifan alarm sounder withoutbattery
back-up isfitted, itis not necessary to
disconnect battery.
7. Remove steeringwheel
SeeSTEERING,
Repair, Steering wheel.
8.Remove 4screws securing instrument panelto
fascia cowl
SeeINSTRUMENTS, Repair,
Instrument panel.
9.Pull instrument panelawayfromfascia and
disconnect speedometer cable,mainharness
multi-plugs, alarmLEDpluglead, heated rear
screen leads,gearbox oiltemperature leadand
immobiliser warninglightlead.
10. Remove instrument panel.
11.Remove alarmsystem 15amp (blue) fusefrom
holder located behindstarterswitch.