Land Rover Defender Workshop Rover Manual

							ELECTRICAL21
REPAIR
MAIN
LIGHT SWITCH
Service repairno-86.65.10
Remove 1. Remove steeringcolumnnacelle
See
STEERING, Repair,Steering columnnacelle.
2.Disconnect mainlightswitch multi-plug from
main harness.
3. Slacken locknutandrelease lightswitch from
slot inmounting bracket.
Refit 4. Fitlight switch inmounting bracket.
5. Reconnect switchmulti-plug.
6. Fitsteering columnnacelle
SeeSTEERING,
Repair, Steering columnnacelle.
HEATED REARSCREEN, REARFOGLAMP AND
HAZARD WARNING SWITCHES
Service repairno-86.65.36 -Heated rearscreen
Service repairno-86.65.65 -Rear foglamp
Service repairno-86.65.50 -Hazard warning
Remove
1. Remove 2screws andwithdraw switchpanel
from lower fascia.
2. Disconnect multi-plugfromrearofswitch.
3. On hazard warning switchonly,remove 2
separate leads.
4. Press inspring retainers andwithdraw switch
from switch panel.
Refit 5. Fitnew switch intoswitch panel.
6. Reconnect switchmulti-plug, andleads if
applicable.
7. Fitswitch paneltolower fascia.    
						

							86ELECTRICAL
22 REPAIR
CIGAR
LIGHTER
Service repairno-86.65.60
Remove
1. Remove 2screws andwithdraw switchpanel
from lower fascia.
2. Disconnect electricalleadsfromswitch housing,
including illumination bulb.
3. Release 2retaining tagsandremove bulbholder
from switch housing.
4. Remove cigarlighter fromswitch housing.
5. Press inretaining tagsandwithdraw housing
from switch panel.
Refit 6. Fithousing toswitch panel.
7. Fitbulb holder toswitch housing.
8. Connect electrical leadsandillumination bulb.
9. Insert cigarlighter intoswitch housing.
10. Fitswitch paneltolower fascia. REAR
SCREEN WIPER/WASHER SWITCH
Service repairno-84.35.34
Remove1. Remove 2screws andwithdraw switchpanel
from lower fascia.
2. Disconnect electricalleadsfromrearscreen
wiper/washer switch.
3. Insert asmall screwdriver inbase ofswitch
knob, pressinretaining lug,and remove knob
from switch spindle.
4. Unscrew lockingring,withwavy washer, and
withdraw wiper/washer switchfrompanel.
Refit 5. Fitswitch toswitch panel.
6. Press inretaining lugand fitknob ontoswitch
spindle.
7. Connect electrical leadstoswitch.
8. Fitswitch panel.   
						

							ELECTRICAL23
REPAIR
HEADLAMP
LEVELLINGSWITCH
Service repairno-86.65.16
Remove
1. Remove 2screws andwithdraw switchpanel
from lower fascia.
2. Disconnect multi-plugfromrearofheadlamp
levelling switch.
3. Remove knobfromswitch spindle.
4. Unscrew retainingnutand withdraw switchfrom
switch panel.
Refit 5. Fitswitch intoswitch panelandsecure with
retaining nut.
6. Fitswitch knob.
7. Connect switchmulti-plug.
8. Fitswitch panel. HEADLAMP
LEVELLINGUNIT
Service repairno-86.41.16
Remove 1. Remove headlamp
SeeHeadlamp.
2.Disconnect headlamplevellingunitharness
plug.
3. Rotate levelling unitanti-clockwise torelease
retaining lugsfrom mounting bracketon
headlamp body.
4. Release levellingunitspindle fromretaining slot
on headlamp bezelandwithdraw unitfrom
mounting bracket.
Refit 5. Fitlevelling unitintomounting bracketandlocate
unit spindle intoslotinheadlamp bezel.
6. Press inunit and rotate clockwise toengage
retaining lugsbehind mounting bracket.
7. Connect levellingunitharness plug.
8. Fitheadlamp
See Headlamp.    
						

							86ELECTRICAL
24 REPAIR
HEADLAMP
BEAMALIGNMENT
Service repairno-86.40.17
Check Check mainbeam alignment usingbeam setting
equipment. Shouldthisnotbeavailable thebeam can
be temporarily checkedandadjusted asfollows:-
1. Position vehicle,unladen, onlevel ground with
tyres correctly inflated,approximately 4meters
from awall orscreen, marked asillustrated
below.
2. The beam centres Aare measured horizontally
on the vehicle anddimension Bvertically from
the ground.
3.Switch onmain beam andadjust setting, as
necessary, withtrimmer screws. On
vehicles fittedwithheadlamp levellingunits,check
and adjust headlamp beamalignment aspreviously
described, withfascia mounted levellingswitchat
position 0.The headlamps canthen beadjusted,
according toload conditions, asfollows:-
Position 0-Driver only,ordriver andallfront seats
occupied (loadspace empty).
Position 1-All seats occupied (loadspace empty).
Position 2-All seats occupied byadults and
loadspace loadedtomaximum rearaxle weight.
Position 3-Driver onlywithloadspace loadedto
maximum rearaxle weight.    
						

							ELECTRICAL25
REPAIR
DIGITAL
DIESELSHUT-OFF VALVE(DDS)
Service repairno-86.77.00
Remove 1. Remove fuelinjection pump
SeeFUEL
SYSTEM, Repair,Fuelinjection pump.
2.Drill out2shear boltssecuring DDSvalve and
clamp, usinga3.2 mm drill, toadepth of
approximately 5mm.
CAUTION: Useadrill bushing toguide the
drill.
3. Using anextractor, removethe2DDS valve
retaining boltsanddiscard.
4. Release DDSvalve fromfuelshut-off solenoid.
5. Remove protective capfrom shut-off solenoid.
6. Unscrew terminalnut,release terminal lead
eyelet andremove DDSvalve. 7.
Remove protective capretainer andrelease
DDS valve clamp frombehind fuelshut-off
solenoid.
Refit 8. Position DDSvalve clamp behind fuelshut-off
solenoid andfitprotective capretainer.
9. FitDDS terminal leadtofuel shut-off solenoid.
Tighten nutto
2Nm (1.5 lbf/ft).
10.Fitprotective captofuel shut-off solenoid,
ensuring terminalleadiscorrecly routedonRH
side ofcap.
11. Secure DDSvalve tofuel cut-off solenoid and
clamp. Tighten newshear boltsprogressively
until heads shear.
12. Fitfuel injection pump
SeeFUEL SYSTEM,
Repair, Fuelinjection pump.   
						

							INSTRUMENTS1
REPAIR
INSTRUMENT
PANEL
Service repairno-88.20.02
Remove 1. Disconnect battery.
2.Remove 4screws securing instrument panelto
fascia cowl.
3. Pull instrument panelawayfromfascia sufficent
to disconnect speedometer cable.
4. Disconnect multi-plugs, electricalleadsand
connections tovehicle alarmsystem, iffitted
See ELECTRICAL, Repair,Vehicle
immobilisation andalarm system
.
5. Withdraw panel,complete withinstruments.
Refit 6. Offer upinstrument panel,connect multi-plugs,
electrical leadsandconnections tovehicle alarm
system, iffitted
See ELECTRICAL, Repair,
Vehicle immobilisation andalarm system
.
7. Connect speedometer cable.
8. Secure instrument panel.
9. Reconnect battery. SPEEDOMETER Service
repairno-88.30.01
Remove 1. Remove 4screws securing instrument panelto
fascia cowl.
2. Pull instrument panelawayfromfascia sufficent
to disconnect speedometer cable.
3.Release bothbulbholders fromspeedometer.
4. Unscrew 2knurled nutsandremove clamps
securing speedometer.
5. Wihdraw speedometer frominstrument panel.
Refit 6. Fitspeedometer intoinstrument paneland
secure withclamps.
7. Fitbulb holders tospeedometer.
8. Connect speedometer cable.
9. Secure instrument paneltofascia cowl.    
						

							88INSTRUMENTS
2 REPAIR
FUEL
ANDTEMPERATURE GAUGE
Service repairno-88.25.26 -Fuel gauge
Service repairno-88.25.14 -Temperature gauge
Remove 1. Remove instrument panel
SeeInstrument
panel
.
2. Release illumination bulbholder anddisconnect
electrical leadsfromgauge.
3. Unscrew knurlednutand remove clamp
securing gauge.
4. Remove earthleadeylet fromgauge stud.
5. Withdraw gaugefrominstrument panel
Refit 6. Fitgauge intoinstrument panel,locateearth
lead, andsecure withclamp.
7. Fitbulb holder andelectrical leads.
8. Fitinstrument panel
SeeInstrument panel.CLOCK
-FASCIA PANEL
Service repairno-88.15.07
Remove 1. Remove 4screws securing instrument panelto
fascia cowl.
2. Pull panel awayfomfascia sufficient to
disconnect speedometer cable.
3.Disconnect electricalleadsandbulb holder from
clock.
4. Unscrew knurlednutand remove clamp
securing clock.
5. Remove clockfrominstrument panel.
Refit 6. Fitclock intoinstrument panelandsecure with
clamp.
7. Fitbulb holder andelectrical leads.
8. Connect speedometer cable.
9. Secure instrument paneltofascia cowl.   
						

							INSTRUMENTS3
REPAIR
CLOCK
-CENTRE DASHPANEL
Service repairno-88.15.07
Remove
1. Remove 2screws andwithdraw switchpanel
from centre dash.
2. Release illumination bulbholder anddisconnect
electrical leadsfromclock.
3. Press inspring retainers andremove clockfrom
panel.
Refit 4. Fitclock intodash panel.
5. Fitelectrical leadsandbulb holder.
6. Secure switchpaneltocentre dash. WARNING
LIGHTPANEL
Service repairno-88.20.18
Remove
1. Remove 2screws andwithdraw warninglight
panel.
2. Disconect bothmulti-plugs.
3. Disconnect illumination bulbleads.
4. Remove warninglightpanel.
Refit 5. Fitillumination bulbleads andmulti-plugs to
warning lightpanel.
6. Secure warning lightpanel toinstrument panel.    
						

							88INSTRUMENTS
4 REPAIR
PRINTED
CIRCUIT-WARNING LIGHTPANEL
Service repairno-88.20.20
Remove 1. Remove warninglightpanel
See Warning light
panel
.
2. Remove 13illumination bulbholders fromlight
panel.
3. Release printedcircuitfromlocating pinsand
remove frompanel seatings.
Refit 4. Fitnew printed circuitoverpanel seatings and
position onlocating pins.
5. Fitillumination bulbstosecure circuit.
6. Fitwarning lightpanel
See Warning light
panel
. FUEL
GAUGE TANKUNIT-REAR FUELTANK,
110/130 Service repairno-88.25.30
WARNING: Ensurethatfuelhandling
precautions giveninSection 01-
Introduction arestrictly adhered towhen
carrying outthefollowing instructions.
Remove 1. Disconnect battery.
2. Remove fuelfiller cap.
3. Remove tankdrain plug,allow fueltodrain intoa
clean container, andrefitplug.
4.On LHside oftank, disconnect fuelsupply pipe
from outlet pipeonfuel gauge unit.
5. Disconnect electricalplugfrom fuelgauge unit.
6. Release lockingringand withdraw fuelgauge
unit from tank, complete withsealing ring.
Refit 7. Insert gauge unitintotank withfloat positioned to
base oftank. Fitnew sealing washer, if
necessary.
8. Secure gaugeunitwith locking ring.
9. Fitelectrical plugandreconnect fuelsupply pipe.
10. Refill fueltank.
11. Reconnect battery.   
						

							INSTRUMENTS5
REPAIR
FUEL
GAUGE TANKUNIT-SIDE FUEL TANK
Service repairno-88.25.31
WARNING: Ensurethatfuelhandling
precautions giveninSection 01-
Introduction arestrictly adhered towhen
carrying outthefollowing instructions.
Remove 1. Disconnect battery.
2. Remove RHfront seatcushion.
3. Release retaining catchandremove seatbase
cover togain access tofuel tank.
4.Disconnect electricalplugfrom fuelgauge unit.
5. Release lockingringand withdraw fuelgauge
unit from tank, complete withsealing ring.
Refit 6. Insert gauge unitintotank withfloat positioned
towards frontoftank. Fitnew sealing washer, if
necessary.
7. Secure gaugeunitwith locking ring.
8. Fitelectrical plug.
9. Fitseat base cover andseat cushion.
10. Reconnect battery.