1996 LAND ROVER DEFENDER auxiliary battery

CHASSIS AND BODY
37
REPAIR REV: 05/9947.Connect leads and plugs to auxiliary switches
and clock.
48.Secure switch panel to lower fascia panel and
switch cover.
49.Position radio housing, if applicable, and feed
radio multi- plug, aerial and speaker leads from
switch cover to radio housing.
50.Secure radio housing to trim panel.
51.Fit radio connections and secure radio in
housing.
52.Fit crash pad to fascia bulkhead.
53.Fit demister vents in crash pad.
54.Fit grab handle to lower fascia panel and secure
to crash pad. Refit Land Rover decal.
55.Connect multi-plugs to rear screen, hazard and
interior lamp switches and fit switch panel to
fascia panel.
56.Fit heater control cable
See HEATING AND
VENTILATION, Repair, Heater control cable -
air distribution
.
57.Fit instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
58.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle
.
59.Fit steering wheel
See STEERING, Repair,
Steering wheel
.
60.Reconnect battery.FRONT UNDERTRAY
Service repair no - 76.11.81 - Front undertray
Service repair no - 76.11.85 - Acoustic pad
Remove
1.Raise vehicle on ramp.
2.Position support under chassis front
crossmember.
3.Lower ramp to give clearance between axle and
undertray.
4.Remove 4 nuts, disconnect propeller shaft from
front axle, and move aside.
5.Remove 2 bolts securing undertray to chassis
front crossmember.
6.Remove nut securing undertray to bump stop
front fixing bolt on both sides.
7.Remove 2 bolts securing sides of undertray to
rear undertray.
8.Pull front undertray forwards to release flanges
from rear undertray.
9.Lower undertray to clear steering box etc. and
manouvre rearwards over axle.
10.Remove front undertray.
11.If necessary, remove 8 fasteners to release
acoustic pad from undertray.

82AIR CONDITIONING
2
REPAIR COMPRESSOR DRIVE BELT
Service repair no - 82.10.02
Remove
1.Disconnect battery.
2.Remove auxiliary drive belt
See ELECTRICAL,
Repair, Auxiliary drive belt.
3.Remove 3 nuts securing drive belt guard to
compressor retaining studs.
4.Slacken 3 belt tensioner retaining bolts.
5.Remove compressor drive belt. Mark direction
on belt if refitting.Refit
6.Fit compressor drive belt.
7.Fit drive belt guard.
8.Fit torque meter to centre of tensioner, apply and
hold a torque of
35 Nm (26 lbf/ft).
9.Tighten tensioner retaining bolts.
10.Rotate crankshaft 2 full turns.
11.Reapply and hold a torque of
35 Nm (26 lbf/ft)
to tensioner, then fully slacken and retighten
tensioner retaining bolts to
25 Nm (18 lbf/ft).
12.Fit auxiliary drive beltSee ELECTRICAL,
Repair, Auxiliary drive belt.
13.Reconnect battery.

ELECTRICAL
11
REPAIR REV: 05/99 Refit
12.Fit new fuse.
13.Position instrument panel to fascia cowl area
and reconnect immobiliser warning light leads,
gearbox oil temperature lead, heated rear screen
leads, alarm LED plug lead, main harness
multi-plugs and speedometer cable,
14.Secure instrument panel to fascia cowl with 4
screws
See INSTRUMENTS, Repair,
Instrument panel.
15.Fit steering wheelSee STEERING, Repair,
Steering wheel.
16.Reconnect battery negative lead.
17.Fit battery access cover.
18.Fit LH front seat cushion.GENERATOR
Service repair no - 86.10.02
Remove
1.Disconnect battery.
2.Remove drive belt
See Auxiliary drive belt.
3.Unscrew 3 fixings, remove heat shield from rear
of generator, and disconnect electrical leads
from generator.
4.Remove generator bottom fixing bolt.
5.Remove long through bolt from top fixing and lift
generator from engine.
Refit
6.Fit generator to engine mounting bracket and
secure with top and bottom fixing bolts.
7.Connect electrical leads.
8.Fit heat shield.
9.Fit drive belt
See Auxiliary drive belt; Refit.
10.Reconnect battery.

86ELECTRICAL
12
REPAIR AUXILIARY DRIVE BELT
Service repair no - 86.10.03
NOTE: If cast lines on tensioner arm and
tensioner spring case are aligned, a new
drive belt must be fitted.
Remove
1.Disconnect battery.
2.Remove fan cowl
See COOLING SYSTEM,
Repair, Fan cowl.
3.Apply ring spanner to tensioner pulley retaining
bolt.
4.Turn spanner to release pulley tension from belt.
5.Detach belt from pulley.
6.Release tensioner.
7.Complete removal of belt. Mark direction on belt
if refitting.
Refit
8.Using ring spanner, release pulley tensioner and
fit new drive belt.
9.Remove ring spanner, drive belt will
automatically tension.
10.Fit fan cowl
See COOLING SYSTEM, Repair,
Fan cowl.
STARTER MOTOR
Service repair no - 86.60.01
Remove
1.Disconnect battery.
2.Disconnect electrical leads from starter solenoid.
3.Remove 3 fixings securing starter motor to
flywheel housing.
4.Withdraw starter motor.
Refit
5.Locate starter motor and secure to flywheel
housing.
6.Reconnect electrical leads to starter solenoid.
7.Reconnect battery.