1996 LAND ROVER DEFENDER battery replacement

ENGINE
7
REPAIR Refit
12.Lightly grease pulley spigot and locate pulley
onto cranshaft.
13.Fit pulley retaining bolt.
14.Fit pulley retainerLRT-12-080and secure with 4
bolts.
15.Tighten pulley nut to
80 Nm (59 lbf/ft)+90°.
16.Remove pulley retainer.
17.Fit drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt; Refit
18.Fit fan cowl.See COOLING SYSTEM, Repair,
Fan cowl
19.Fit viscous coupling and fan.See COOLING
SYSTEM, Repair, Viscous coupling and fan
20.Fit intercooler to induction manifold hose.
21.Fit radiator top hose.
22.Refill cooling system.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
23.Reconnect battery.FRONT COVER PLATE AND SEAL
Service repair no - 12.65.01
Remove
1.Disconnect battery.
2.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6.Remove fan cowl.See COOLING SYSTEM,
Repair, Fan cowl
7.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
8.Remove crankshaft pulley.See Crankshaft
pulley
9.Remove 14 bolts securing front cover plate. Note
that top 2 bolts also retain thermostat hose clips.
10.Remove cover plate complete with gasket.
11.Remove small gasket from centre bolt boss.
Seal replacement
12.Remove worn seal from cover and clean recess.
13.Support cover and fit new seal, open side fitted
into recess, using special toolLRT-12-077.

STEERING
7
REPAIR POWER STEERING PUMP
Service repair no - 57.20.14
Remove
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
.
1.Disconnect battery.
2.Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan
.
3.Restrain steering pump pulley, slacken but do
not remove 3 bolts securing pulley.
4.Remove drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
5.Remove bolts and remove pulley.
6.Position suitable container beneath steering
pump.
7.Slacken retaining clip and disconnect return
hose from steering pump.
8.Disconnect high pressure pipe from steering
pump.
9.Allow steering fluid to drain into container.
CAUTION: Plug all connections to prevent
ingress of dirt.
10.Remove 4 bolts securing steering pump bracket
to engine auxiliary mounting bracket.
11.Remove pump and bracket assembly.
12.Remove 3 bolts and detach mounting bracket
from pump.
Refit
13.Fit mounting bracket to replacement steering
pump. Tighten bolts to
9 Nm (7 lbf/ft).
14.Fit pump and bracket to auxiliary mounting
bracket. Tighten bolts to
35 Nm (26 lbf/ft).
15.Connect high pressure feed pipe to steering
pump and tighten to
20 Nm (15 lbf/ft).
16.Connect return hose to steering pump. Tighten
retaining clip to
3 Nm (2 lbf/ft).
17.Position pulley to steering pump, coat threads of
bolts with Loctite 242; fit but do not fully tighten
bolts.
18.Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
19.Restrain steering pump pulley, tighten bolts to
10
Nm (7lbf/ft).
20.Fit viscous fan unitSee COOLING SYSTEM,
Repair, Viscous coupling and fan
.
21.Bleed power steering system
See Power
steering system - bleed
.
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.02
NOTE: For details of drive belt remove and
refit
See ELECTRICAL, Repair, Auxiliary
drive belt
.

ELECTRICAL
1
DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of electrical
connections at all times. Any incorrect connections
made when reconnecting cables may cause
irreparable damage to semi-conductor devices used in
generator and regulator. Incorrect polarity would also
seriously damage any transistorized equipment such
as a radio.
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect battery negative lead first. If
positive lead is disconnected with negative lead in
place, accidental contact of wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery positive lead should be
connected first.
GENERATOR
The generator is a three phase, field sensed unit. The
rotor and stator windings produce three phase
alternating current, AC, which is rectified to direct
current, DC. The electronic voltage regulator unit
controls generator output voltage by high frequency
switching of the rotor field circuit. Use only correct
replacement drive belt. Occasionally check that
engine and generator pulleys are accurately aligned.
It is essential that good electrical connections are
maintained at all times. Of particular importance are
those in the charging circuit (including those at
battery) which should be occasionally inspected to
see that they are clean and tight. In this way any
significant increase in circuit resistance can be
prevented.Do not disconnect battery cables while engine is
running or damage to semi-conductor devices may
occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while engine is running.
The electronic voltage regulator employs micro-circuit
techniques resulting in improved performance under
difficult service conditions. The whole assembly is
encapsulated in silicone rubber and housed in an
aluminium heat sink, ensuring complete protection
against adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give required regulating voltage range of 14.2±0.2
volts, and no adjustment is necessary. The only
maintenance needed is occasional check on terminal
connections and wiping with a clean dry cloth.
The generator system provides for direct connection
of a charge (ignition) indicator warning lamp, and
eliminates the need for a field switching relay or
warning light control unit. In the event of bulb failure,
an 'exciter' voltage is supplied through a resistor,
wired in parallel to the bulbs, ensuring that generator
output is maintained. The lamp should be checked
regularly.
When using rapid charge equipment to re-charge
battery, the battery must be disconnected from the
vehicle.

86ELECTRICAL
2
DESCRIPTION AND OPERATION VEHICLE IMMOBILISATION AND ALARM SYSTEM
A sophisticated engine immobilisation and anti-theft
alarm system is offered on the Land Rover Defender
300 Tdi vehicle range, which incorporates the
following features:
Perimeter protection
This part of the alarm system protects side doors,
bonnet and rear door against unauthorised entry -
alarm sounding if any one of these apertures is
opened without alarm first being disarmed.
Interior protection
Also known as volumetric protection, this part of the
system protects space inside the vehicle. Once
armed, the alarm will sound if a door is opened, or if
movement is detected inside the vehicle.
Engine immobilisation
The engine is immobilised electronically whenever the
alarm system is armed. Even if the alarm has not
been armed, engine immobilisation will occur
automatically thirty seconds after the driver's door is
opened, or five minutes after the starter switch is
turned to position '0'.
ALARM SYSTEM COMPONENTS
Electronic control unit (ECU)
The ECU is the alarm system brain and controls all
vehicle immobilisation and alarm functions. It
responds to the inputs received, by supplying suitable
outputs to indicate status of the alarm system or
activating relevant warning devices. unit is located
under fascia behind instrument binnacle.
Handset and key
The handset is the primary source of control for the
alarm system i.e. it arms and disarms the alarm
components. The key can be used to override engine
immoblisation if the handset is lost or fails to operate,
seeEngine immobilisation override.The handset battery should last for approximately
three years dependent upon use. The following
symptoms will be noticed when the battery requires
replacement:
1.The handset will only work every other operation
while disarming.
2.The direction indicator lamps will not flash when
the alarm is disarmed.
For battery replacement procedure, seeHandset
Battery.
Passive coil
The passive coil is fitted on the starter switch and
activates a receiving coil in the handset, causing it to
automatically transmit a remobilisation signal to the
ECU.
Aerial
The aerial is integral within the alarm system harness
and supplies the ECU with the signal received from
handset.
Immobilisation spider
The immobilisation spider provides an interface
between ECU and immobilised areas of the vehicle.
This is installed in a sealed (safe) box inside the
vehicle battery box.
Digital diesel shut-off valve - 97 MY
When fitted, the digital diesel shut-off valve
immobilises the fuel injection pump by preventing
power reaching the fuel shut-off solenoid,
See
Immobilisation and alarm system circuit diagram -
with DDS
.