1996 LAND ROVER DEFENDER ECU

BRAKES
3
OVERHAUL
8.Remove guide ring from mouth of master
cylinder which supports primary plunger
assembly and place to one side, this component
is not part of master cylinder service kit and is to
be refitted on assembly of unit.
9.Pull primary plunger assembly out of master
cylinder.
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
10.The secondary plunger assembly will remain at
bottom of master cylinder bore, plunger can be
easily expelled by tapping assembly on a piece
of timber until plunger appears at cylinder mouth,
carefully pull plunger from master cylinder.
11.If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
expel it from bottom of master cylinder bore and
discard.12.Clean all parts with Girling cleaning fluid or
unused brake fluid and place cleaned parts on to
a clean sheet of paper. Inspect cylinder bore and
plungers for signs of corrosion, ridges and score
marks. Provided working surfaces are in perfect
condition, new seals from a Girling Service
repair kit may be used.
Renewing secondary plunger seals
A.Springs
B.Seal retainer
C.Recuperating seal (primary cup)
D.Washer
E.'L' seal
13.Remove components above from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded and polished is required to
remove 'L' seal. DO NOT damage
secondary plunger.
14.Coat new seals in unused brake fluid and firstly
fit 'L' seal to plunger.
15.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.

70BRAKES
4
OVERHAUL Assembling master cylinder
CAUTION: It is important that the following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
NOTE: Thoroughly check that no debris is
lodged in fluid passageways and drillings.
If debris is found, carefully remove,
re-clean cylinder and re-check.
16.Fit new swirl tube to bottom of cylinder bore.
17.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
18.Fit primary plunger assembly using same
method as for secondary plunger, push plunger
down bore.
19.Fit original guide ring to support primary plunger.
20.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: 'O' ring should not be rolled
down outer location surface of master
cylinder but should be slightly stretched
and eased down cylinder and into its groove. Do
not over stretch seal.21.Fit a new retaining ring on outer surface of
master cylinder ensuring that serrations of ring
are facing mounting flange.
22.Fit two new reservoir seals in their respective
ports.
23.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger guide ring.
24.Lubricate vacuum seal with brake fluid, fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange. Do
not adjust transfer housing after fitting.
25.Lubricate a new water ingress seal with brake
fluid, slightly stretch seal and ease it down
housing until seal is in correct position between
housing and flange.
26.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 3.
27.Fit master cylinder to servo
See Repair,
Master cylinder
.
28.Reconnect battery, and road test vehicle.

CHASSIS AND BODY
3
REPAIR
Refit
7.Remove any trim fasteners held in door panel.
Refit or insert new clips to trim panel.
8.Ensure that anti-vibration pads are in position
and offer-up trim casing to door. Align fasteners
with holes in door and firmly push trim into
position.
9.Fit bezels to locking button and remote control
lever.
10.Fit single screw behind remote control lever.
11.Fit door pull and secure with 2 screws and
finisher caps.
12.Fit window regulator handle and retain with
single screw and finisher.WINDOW REGULATOR - REAR SIDE DOOR
Service repair no - 76.31.45
Remove
1.Remove door trim casing
See Door trim casing
.
2.Remove plastic sheet.
3.Temporarily fit handle, wind window up to its
fullest extent and support glass with a length of
timber, to prevent it falling when removing
regulator.
4.Remove 4 screws retaining regulator to
mounting panel and withdraw regulator whilst
sliding lifting arm button from lifting channel. To
assist this operation, remove timber and lower
glass.

76CHASSIS AND BODY
4
REPAIR
Refit
5.Insert lifting arm button into lifting channel.
6.Position regulator so that fixing holes line-up with
holes in mounting panel.
7.Secure with 4 screws and tighten evenly.
8.Temporarily fit handle and check that glass can
be raised and lowered smoothly without tight
spots.
9.Fit plastic sheet.
10.Fit door trim
See Door trim casing.EXTERIOR HANDLE - REAR SIDE DOOR
Service repair no - 76.58.02
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel back sufficient of plastic sheet to gain
access to handle mechanism.
3.Disconnect actuating rod from handle operating
lever.
4.Remove 2 screws and withdraw handle and
bezels.
Refit
5.Fit handle to door ensuring that both bezels are
in position - flat faces towards door and secure
with 2 screws.
6.Connect actuating rod to handle operating lever
and secure with spring clip.
7.Re-seal plastic sheet.
8.Fit door trim casing
See Door trim casing.

CHASSIS AND BODY
5
REPAIR SILL LOCKING BUTTON - REAR SIDE DOOR
Service repair no - 76.37.30
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel back sufficient of plastic sheet to reveal
mechanism.
3.Release spring clip securing button to operating
rod and withdraw rod from button.
4.Remove 2 screws securing button to door panel
and remove button.
Refit
5.Secure locking button assembly to door panel
with 2 screws.
6.Fit operating rod to button assembly and secure
with spring clip.
7.Re-seal plastic sheet and fit door trim casing
See Door trim casing.REMOTE CONTROL LEVER - REAR SIDE DOOR
Service repair no - 76.37.32
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel-back sufficient of plastic sheet to gain
access to remote lever.
3.Remove spring clip and disconnect control rod
from locking button.
4.Release spring clip and disconnect short locking
button control rod from latch mechanism.
5.Disconnect long remote control rod from latch
assembly.

76CHASSIS AND BODY
6
REPAIR 6.Remove 2 screws securing remote control lever
to mounting panel.
7.Release control rods from plastic retaining clips
located in mounting panel.
8.Withdraw remote control lever and rods from
door.
Refit
9.Fit plastic retaining clips to rod assembly into
position and secure with 2 screws.
10.Connect control rods to latch assembly and
secure with clips.
11.Fit plastic retaining rod clips to mounting panel.
12.Connect control rod to locking button and secure
with clip.
13.Re-seal plastic sheet and fit door trim casing
See Door trim casing.DOOR LATCH - REAR SIDE DOOR
Service repair no - 76.37.13.
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel-back sufficient of plastic sheet to reveal
latch.
3.Release remote control lever rod from latch
assembly.
4.Disconnect door outer handle control rod from
latch assembly.
5.Disconnect door locking button remote control
rod from latch mechanism.
6.Remove 3 retaining screws and withdraw latch
assembly from door.
Refit
7.Fit latch assembly to door and secure with 3
screws, noting that uppermost screw is longer.
8.Connect remote control levers to latch
mechanism reversing instructions 3, 4 and 5.
9.Re-seal plastic sheet and fit door trim casing
See Door trim casing.

76CHASSIS AND BODY
8
REPAIR
11.Remove 2 self-tapping screws from each side
and remove glass lower channels.
12.Remove inner and outer weather strips from
door sill.
13.Lower glass down to bottom of door, lift glass
over lower edge and withdraw from door.
14.Remove lift channel from glass, if necessary.Refit
15.Fit lift channel to new glass, if necessary.
16.Insert glass into lower channels and carefully
push glass up to top of frame.
17.Secure lower channels with 4 self-tapping
screws. Ensure that screw heads are screwed
down firmly below bottom of channels to prevent
damage to glass.
18.Fit door check rod and bend end stop back to
closed position.
19.Fit check stop torsion bar and secure with 2 nuts
and bolts.
20.Fit water channel and secure with single
self-tapping screw.
21.Fit mounting panel complete with rods and
remote control lever.
22.Connect control rods to latch and door outer
handle mechanism.
23.Fit door sill locking button and connect control
rod
See Sill locking button.
24.Fit window regulator
See Window regulator.
25.Fit door inner and outer sill wear strips.
26.Fit and re-seal plastic sheet.
27.Fit door trim casing
See Door trim casing.
28.Connect door check rod to door post.

CHASSIS AND BODY
9
REPAIR MOUNTING PANEL - FRONT DOOR
Service repair no - 76.11.28
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove 4 screws securing window regulator to
mounting panel.
3.Remove 5 screws securing mounting panel to
door frame.
4.Release remote control lever rod from latch
mechanism and from plastic clip in mounting
panel.
5.Slide window regulator arm from mounting panel
channel and remove panel with remote control
lever and rod.
Refit
6.Engage window regulator arm in mounting panel
channel.
7.Connect remote control rod to latch mechanism
and secure with clip.
8.Fit mounting panel and retain with 5 screws.
9.Secure window regulator to mounting panel with
4 screws.
10.Raise and lower window to check for free
movement.
11.Fit plastic sheet, and door trim casing
See
Door trim casing
.